ABB Installation Products K656LR-F0220-SG3 15/25kV, 600 Amp, Elbow with Sealing Kit, With Test Point (includes Insulating Plug…

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

This guide provides detailed instructions for the safe and proper installation of Elastimold 655/675LR and K655/K675LR deadbreak elbow connectors, designed for fully shielded, submersible cable connections to high voltage apparatus on 15kV and 25kV class systems.

Estimated time: 2h

1. Initial Safety and Inspection

   DANGER: Ensure all apparatus are de-energized before beginning installation. Do not touch or move energized products in the work area. This product must be installed only by competent personnel trained in high voltage electrical equipment safety practices. Inspect the contents of the connector package to ensure all parts are complete and undamaged. Verify all components are compatible with the cable and mating products.

2. Prepare Cable for Installation

   Assemble the cable in its final position, allowing sufficient slack for elbow removal. For concentric neutral cable, unwind the concentric neutral wires. Cut the cable 1-3/4 inches (45mm) from the centerline of the mating product. Clean the outer surface of the cable for a distance of 24 inches (610mm) or up to the bent back concentric neutral wires.

3. Cable Jacket and Shield Preparation

   Remove the outer jacket (if applicable) and prepare the cable according to the specific cable type (e.g., non-jacketed concentric neutral, jacketed shield wires, flat metallic tape shield, fabric tape shield, or longitudinally corrugated shield). Refer to the provided diagrams for precise dimensions for cable insulation, semi-con shield, and tape marker placement. If using a 20MA/21MA grounding device, 600ECS Jacket Cable Seal, or 10TL cable shield adapter, follow their respective installation instructions for cable preparation.

4. Install Cable Adapter

   Bevel the end of the cable insulation at a 45-degree angle, approximately 1/4 inch (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.

5. Prepare Conductor Length

   Carefully remove the protruding cable insulation by cutting it even with the end of the cable adapter. Avoid cutting or nicking the cable adapter or the conductor. The exposed conductor length must be between 4-1/4 inches and 4-9/16 inches (108mm-116mm). If the length is outside this range, re-do the assembly.

6. Crimp Compression Lug

   For copper conductors, fully insert the conductor into the compression lug. For aluminum conductors, wire brush the conductor immediately before fully inserting it into the compression lug. Measure the 'Check Dimension' before crimping; it must be less than 6-3/8 inches. Crimp the compression lug following the instructions supplied with the lug. After crimping, wipe all excess inhibitor from the lug and cable adapter surface. The distance from the end of the compression lug to the cable adapter must be between 6-3/8 inches to 7-1/8 inches (162mm-181mm). Re-do if outside this range.

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 remains 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 any protective caps from both 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 the mating part. Clean and lubricate both the elbow and the mating part with the supplied lubricant, ensuring surfaces remain clean.

9. Connect Elbow to Mating Part

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

10. Connect Opposite End of Elbow

    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 specific instructions provided with that mating part. CAUTION: When constructing 600amp L-Kits, ensure each component is tightened to its specified torque.

11. Install Insulating Plug (if used)

    If an insulating plug is used as a mating part, clean and lubricate the inner surface of the voltage detection cap. Place the cap onto the elbow and push down firmly until it snaps into place.

12. Ground the Cable Shield

    Insert one end of a No. 14 AWG Copper wire (or equivalent ampacity) through the grounding eye and twist to form 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 either through a grounding device (following its instructions) or an alternate method. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

13. Perform Voltage Test

    The Elastimold deadbreak elbow connector features an integral capacitance test point. To test for voltage, remove the test point cap with a hotstick, peeling it off at an angle. WARNING: The voltage test point is a capacitance device, not directly connected to the conductor. Do not use conventional voltage measuring equipment. Use a suitable sensing device designed for capacitive test points and follow its manufacturer's directions. Contamination or incorrect equipment can give a false 'no voltage' indication; treat the elbow as energized until the 'no voltage' indication is confirmed by other means to prevent serious injury. After testing, clean and lubricate the inside surface of the cap with silicone lubricant and replace it on the test point.

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