ABB Installation Products K656LR-N0410-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 655/675LR and K655/K675LR Deadbreak Elbow Connectors, including cable preparation, lug crimping, and connection to mating apparatus.

Estimated time: 1h 30m

1. De-energize Apparatus and Inspect Parts

   DANGER: Ensure all apparatus is de-energized before beginning installation or removal of any parts. Inspect all components for damage, verify their rating, and confirm compatibility with mating parts. Remove any protective shipping covers and replace them with appropriate HV insulated caps or connectors before submerging or energizing the circuit.

2. Assemble and Clean Cable

   Assemble the cable in its final position, ensuring 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. Thoroughly clean the outer surface of the cable for a distance of 24 inches (610mm) or up to the bent back concentric neutral wires.

3. Prepare Cable End

   Remove the outer jacket (if applicable) and prepare the cable according to its specific type (e.g., non-jacketed concentric neutral, jacketed shield wires, flat metallic tape shield, fabric tape shield, or longitudinally corrugated shield) as detailed in the product documentation. Follow specific instructions for any grounding devices or cable seals being used.

4. Install 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.

5. Prepare Conductor and Crimp 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). For aluminum conductors, wire brush the conductor immediately before insertion. Fully insert the conductor into the compression lug. Measure the 'Check Dimension' before crimping (should be less than 6-3/8 inches). Crimp the compression lug according to the supplied instructions. Wipe all excess inhibitor from the lug and cable adapter surface. Verify the distance from the end of the lug to the cable adapter after crimping is between 6-3/8 inches and 7-1/8 inches (162mm-181mm).

6. Install Elbow onto Cable Adapter

   Lubricate the cable adapter and the inside of the elbow's 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.

7. Prepare Mating Products for Connection

   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. 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, ensuring surfaces remain clean.

8. Connect Elbow to Mating Part

   Push the elbow onto the mating part, carefully lining up the hole in the compression lug with the stud on the mating part.

9. Connect Opposite End Mating Product

   Clean and lubricate the mating part intended 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 specific instructions provided with that mating part.

10. 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 firmly until it snaps into place.

11. Ground the Cable Shield

    Insert one end of a grounding wire (at least equivalent to No. 14 AWG Copper) through the grounding eye and twist to form a small loop, taking care not to damage the eye. Connect this wire to ground using a suitable connector. The cable shield must be grounded; follow instructions supplied with any grounding device or use an alternate method. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

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

    CAUTION: If constructing 600amp L-Kits, ensure that each component is tightened to the specified torque as per the instructions provided with the kit.

13. Perform Voltage Test

    WARNING: The voltage test point is a capacitance device, not directly connected to the conductor. Do not use conventional voltage measuring equipment. Remove the test point cap with a hotstick, peeling it off at an angle. Test for voltage using a suitable sensing device designed for capacitive test points. Treat the elbow as energized until a 'no voltage' indication is confirmed by other means to prevent serious or fatal injury. After testing, clean and lubricate the inside surface of the cap with silicone lubricant and replace it on the test point.

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