ABB Installation Products K656LR-L0300-S 15/25kV 600 Amp Series Deadbreak Elbow with Test Point (with 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 600-ampere and 900-ampere deadbreak elbow connectors on 15kV and 25kV class systems. It covers cable preparation, connector assembly, and grounding.

Estimated time: 2h

1. Prepare for Installation 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. Inspect all parts for damage, proper rating, and compatibility with mating parts. Ensure all required tools and supplies are at hand and maintain cleanliness throughout the procedure. Remove any protective shipping covers and replace with appropriate HV insulated caps or connectors before submerging or energizing the circuit.

2. Prepare the Cable

   Assemble the cable in its final position with enough slack for elbow removal. For concentric neutral cable, unwind the 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 (if applicable) and prepare the cable layers to the specified dimensions: 9-3/4 inches (248mm), 10-3/4 inches (273mm), and 12-3/4 inches (324mm) for the cable insulation, semi-con shield, and outer jacket/shield wires respectively. Refer to specific instructions for 20MA/21MA grounding devices, 600ECS Jacket Cable Seals, UNISHIELD, or Lead Sheath cables if applicable.

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, working towards the semi-con shield. Install the cable adapter, small end first, until it is flush with the edge of the tape marker.

4. 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. Verify the exposed conductor length is between 4-1/4 inches and 4-9/16 inches (108mm-116mm); otherwise, redo the assembly. For aluminum conductors, wire brush the conductor immediately before insertion. Fully insert the conductor into the compression lug. Measure the 'Check Dimension' before crimping; it should be less than 6-3/8 inches. 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 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 it cannot advance further. Ensure the cable adapter remains flush with the tape marker; if not, reposition the cable adapter. Remove the tape marker.

6. Connect to 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 supplied lubricant, ensuring surfaces remain 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 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.

7. Install Insulating Plug (Optional)

   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 it snaps into place. Proceed to the voltage test directions.

8. Ground the Cable Shield

   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 this wire to ground using a suitable connector. The shield of the cable must be grounded; follow instructions supplied with the grounding device or use an alternate method if no device is used. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

9. Perform Final Torque Check (for 600-amp L-Kits)

   CAUTION: When constructing 600-amp L-Kits, ensure each component is tightened to the specified torque according to the instructions provided with the kit.

10. Conduct 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. Follow the manufacturer’s directions for the specific meter used. Test with a suitable sensing device designed for capacitive test points to determine if the cable is energized. Contamination, moisture, dirt, or incorrect equipment can cause a false 'no voltage' indication. To prevent serious or fatal injury, treat the elbow as energized until the 'no voltage' 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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