ABB Installation Products K656LR-H0290-S 15/25kV 600 Amp Series Deadbreak Elbow with Test Point (with Insulated Plug, Cap, Stud…

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

This guide provides step-by-step instructions for the safe and proper installation of Elastimold 655/675LR and K655/K675LR deadbreak elbow connectors on high voltage cable systems. It covers cable preparation, connector assembly, and final connection.

Estimated time: 1h 30m

1. Prepare the Cable for Installation

   DANGER: Ensure all apparatus is de-energized before starting installation. This product must be installed only by competent personnel trained in high voltage electrical safety practices. Assemble the cable in its final position, ensuring sufficient slack for elbow removal. For concentric neutral cable, unwind the neutral wires. Cut the cable 1-3/4” (45mm) from the center line of the mating product. Clean the outer surface of the cable for 24” (610mm) or up to the bent back concentric neutral wires. Refer to specific product instructions for cable jacket removal, shield connection, and grounding if using a 20MA/21MA grounding device, 600ECS Jacket Cable Seal, or 10TL cable shield adapter. Otherwise, remove the outer jacket (if applicable) and prepare the cable according to the provided diagrams for your cable type (e.g., non-jacketed concentric neutral, jacketed shield wires, flat metallic tape shield, fabric tape shield, or longitudinally corrugated shield).

2. Prepare Cable Insulation and Install 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.

3. Prepare Conductor and Crimp Compression Lug

   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); otherwise, redo the assembly. 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 (it should be less than 6-3/8”). Crimp the compression lug following the instructions supplied with the lug. Wipe all excess inhibitor from the compression lug and cable adapter surface after crimping. The distance from the end of the compression lug to the cable adapter after crimping should be between 6-3/8” to 7-1/8” (162mm-181mm); otherwise, redo the assembly.

4. 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. If not, reposition the cable adapter. Remove the tape marker.

5. Connect Elbow to Mating Product

   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 already equipped with a stud. Clean and lubricate both the elbow and the mating part with the supplied lubricant, ensuring surfaces remain clean. Push the elbow onto the mating part, carefully aligning the hole in the compression lug with the stud on the mating part.

6. Connect Opposite End of Elbow (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 the instructions supplied with that specific mating part. CAUTION: When constructing 600-amp L-Kits, ensure each component is tightened to the specified torque per instructions.

7. Install Insulating Plug and Ground Cable Shield

   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. 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, 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 it according to the instructions supplied with the grounding device, or through an alternate method if no device is used. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

8. Perform Voltage Test (Optional but Recommended)

   The ELASTIMOLD® deadbreak elbow connector is equipped with an integral capacitance test point. To use it, remove the test point cap with a hotstick, peeling it off at an angle rather than pulling directly in line. WARNING: The voltage test point is a capacitance device and is not directly connected to the conductor. Do not use conventional voltage measuring equipment. Follow the manufacturer’s directions for the specific meter used. Test with a suitable sensing device, designed for use with separable connectors manufactured with capacitive test points, to determine if the cable is energized. Contamination, moisture, dirt, or incorrect measuring equipment can provide a false 'no voltage' indication. 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, clean and lubricate the inside surface of the cap with silicone lubricant and replace it on the test point.

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