K656LR-H0280

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

This guide provides step-by-step instructions for the installation and wiring of 600-ampere or 900-ampere deadbreak elbow connectors on 15kV and 25kV class systems. Ensure all apparatus are de-energized before starting.

Estimated time: 1h 30m

1. Ensure Safety and Inspect Components

   DANGER: All apparatus must be de-energized during installation or removal of parts. Do not touch or move energized products in the work area. Failure to follow these instructions will result in serious or fatal injury. This product must be installed only by competent personnel trained in high voltage safety practices. Inspect all package contents and components for completeness, damage, proper fit with the cable, and compatibility with mating products.

2. Prepare the Cable for Connection

   Position the cable in its final assembled position with enough slack to provide adequate clearance for removing the elbows. 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. Remove the outer jacket (where applicable) and prepare the cable according to the specific cable type (e.g., non-jacketed, jacketed shield wires, flat metallic tape shield, fabric tape shield, or longitudinally corrugated shield).

3. Install the Cable Adapter and Prepare Conductor

   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, 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. Remove the protruding cable insulation by cutting it even with the end of the cable adapter, ensuring not to cut or nick the cable adapter or the conductor. The length of exposed conductor should be between 4-1/4 inches and 4-9/16 inches (108mm-116mm); otherwise, redo the assembly.

4. Crimp the 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 into the compression lug. Measure the 'Check Dimension' before crimping; this dimension should be less than 6-3/8 inches. Crimp the compression lug following the crimping instructions supplied with the lug. After crimping, wipe all excess inhibitor from the compression lug and cable adapter surface. The distance from the end of the compression lug to the cable adapter after crimping should be between 6-3/8 inches to 7-1/8 inches (162mm-181mm); otherwise, redo the assembly.

5. Install the Elbow Connector

   Lubricate the cable adapter and the inside of the elbow cable entrance. Install the elbow onto the cable adapter until the elbow cannot advance further. Make sure the cable adapter is still flush with the tape marker. If not, reposition the cable adapter. Remove the tape marker.

6. Connect 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 the mating part is not equipped with a stud. Clean and lubricate both the elbow and the mating part with the lubricant supplied. Push the elbow onto the mating part, lining up the hole in the compression lug with the stud on the mating part. For the opposite end of the elbow, clean and lubricate the mating part, insert it into the elbow, engage the threads, and hand tighten. Torque the mating part according to the instructions supplied with the mating part. CAUTION: When constructing 600amp L-Kits, be sure to tighten each component to specified torque per instructions provided.

7. 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. Place the cap on the elbow and push down hard until the cap snaps into place. Follow voltage test directions below.

8. Ground the Cable Shield

   Insert one end of a piece of wire with ampacity at least equivalent to No. 14 AWG Copper through the grounding eye and twist to make a small loop, ensuring 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. If no grounding device is used, the shield must be grounded through an alternate method. It is also recommended that the jacket of the cable be waterproofed at this point to prevent moisture from entering the cable.

9. Perform Voltage Test

   Remove the test point cap with a hotstick, peeling it off at an angle rather than pulling directly in line with the test point assembly. WARNING: The voltage test point is a capacitance device and is not directly connected to the conductor. Do not use conventional voltage measuring equipment. Test with a suitable sensing device, made for use with separable connectors manufactured with capacitive test points, to determine if the cable is energized, following the manufacturer’s directions for the meter. 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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