ABB Installation Products K656LR-L0230-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 comprehensive instructions for the safe installation, cable preparation, and connection of Elastimold 655/675LR and K655/K675LR deadbreak elbow connectors to high voltage apparatus, ensuring proper assembly and grounding.

Estimated time: 1h 30m

1. Pre-Installation Safety and Inspection

   DANGER: All apparatus must be de-energized during installation or removal of parts. Do not touch or move energized products in the work area. This product should be installed only by competent personnel trained in good safety practices involving high voltage electrical equipment. Inspect all parts for damage, correct rating, and compatibility with mating parts. If the product is supplied with protective shipping cover(s), remove them and replace with the appropriate HV insulated cap(s) or connector(s) before submerging or energizing the circuit. Ensure all required tools and supplies are at hand and maintain cleanliness throughout the procedure.

2. Prepare the Cable for Connection

   Assemble the cable in its final 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. Prepare the cable by removing the outer jacket (where applicable) and insulation according to the specific cable type and dimensions provided in the documentation (e.g., 9-3/4 inches insulation, 10-3/4 inches semi-con shield, 12-3/4 inches tape marker).

3. Install the 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, 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.

4. Prepare the Conductor and Install Compression Lug

   Remove any 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 should be between 4-1/4 inches and 4-9/16 inches (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; this dimension should be less than 6-3/8 inches. Crimp the compression lug following the crimping 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 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 the Elbow to Mating Apparatus

   DO NOT CONNECT OR DISCONNECT MATING PRODUCTS WHILE ENERGIZED. DO NOT ENERGIZE WHILE DISCONNECTED. Remove protective caps from both 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, keeping surfaces clean. Push the elbow onto the mating part, lining up the hole in the compression lug with the stud on the mating part. If connecting an opposite end mating product (for splicing or tapping), clean and lubricate it, then insert it into the elbow, engage the threads, and hand tighten. Torque the mating part according to the instructions supplied with that mating part.

7. Install Insulating Plug (If Applicable) and Ground the Cable

   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 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. CAUTION: When constructing 600amp L-Kits, be sure to tighten each component to specified torque per instructions provided.

8. Perform Voltage Test (Post-Installation Check)

   WARNING: THE VOLTAGE TEST POINT IS A CAPACITANCE DEVICE; IT IS NOT DIRECTLY CONNECTED TO THE CONDUCTOR. Do not use conventional voltage measuring equipment. Follow the manufacturer’s directions for the meter that is used. 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. Test with a suitable sensing device, made for use with separable connectors manufactured with capacitive test points, to determine if the cable is energized. WARNING: 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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