ABB Installation Products K656LR-H2270 15/25kV, 600 Amp, DeadBreak, Elbow with Test Point (includes Insulated Plug, Cap, Stud…

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How to Install Elastimold Deadbreak Elbow Connectors (655/675LR & K655/K675LR)

This guide provides step-by-step instructions for the safe and proper installation of Elastimold 655/675LR and K655/K675LR series deadbreak elbow connectors, including cable preparation, lug crimping, and connection to mating apparatus.

Estimated time: 2h

1. Prepare for Installation and Ensure Safety

   De-energize all apparatus in the work area. Verify package contents, component fit, and compatibility with mating parts. Remove any protective shipping covers and replace with appropriate HV insulated caps or connectors if the circuit will be submerged or energized. Gather all required tools and maintain a clean work environment. This product must be installed only by competent personnel trained in high voltage electrical equipment safety practices. Failure to follow instructions can result in serious injury or death.

2. Prepare the Cable

   Assemble the cable in its final position, ensuring enough slack for elbow removal. Unwind concentric neutral wires (if applicable). Cut the cable 1-3/4” (45mm) from the centerline of the mating product. Clean the outer surface of the cable for 24” (610mm) or up to the bent-back concentric neutral wires. Follow specific cable preparation instructions (e.g., remove outer jacket, prepare semi-con shield) based on cable type, referring to diagrams or other product instructions if using grounding devices or shield adapters.

3. Install Cable Adapter and Prepare Conductor

   Bevel the end of the cable insulation at a 45-degree angle, approximately 1/4” (6mm) back. Thoroughly clean and 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, cutting it even with the end of the cable adapter. Do not cut or nick the cable adapter or conductor. Verify the exposed conductor length is between 4-1/4” and 4-9/16” (108mm-116mm); redo if incorrect.

4. Crimp the 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 (this dimension should be less than 6-3/8”). Crimp the compression lug according to the instructions supplied with the lug, locating the first crimp on the end closest to the cable. Wipe all excess inhibitor from the compression lug and cable adapter surface after crimping. Verify the distance from the end of the compression lug to the cable adapter is between 6-3/8” to 7-1/8” (162mm-181mm) after crimping; redo if incorrect.

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 it cannot advance further. Ensure the cable adapter remains flush with the tape marker; reposition if necessary. Remove the tape marker.

6. Connect to Mating Apparatus

   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 the mating part. Clean and lubricate both the elbow and the mating part with the supplied lubricant, keeping surfaces clean. Push the elbow onto the mating part, aligning the hole in the compression lug with the stud on the mating part. Clean and lubricate the mating part for the opposite end of the elbow. Insert the mating part into the elbow, engage the threads, and hand tighten. Torque the mating part according to its specific 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 it snaps into place.

7. Ground the Cable Shield and Waterproof

   Insert one end of a grounding 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 the grounding wire to ground using a suitable connector. Ground the cable shield according to the instructions supplied with the grounding device. If no grounding device is used, ground the shield through an alternate method. Waterproof the cable jacket at this point to prevent moisture from entering the cable. When constructing 600amp L-Kits, ensure each component is tightened to the specified torque per instructions.

8. Perform Voltage Test (If Applicable)

   If an insulating plug with a capacitive test point is used, remove the test point cap with a hotstick, peeling it off at an angle. The voltage test point is a capacitance device and is not directly connected to the conductor. Do not use conventional voltage measuring equipment. Use a suitable sensing device designed for capacitive test points. Contamination or incorrect equipment can provide a false 'no voltage' indication. Treat the elbow as energized until the 'no voltage' indication is confirmed by other means to prevent serious or fatal injury. 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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