ABB Installation Products K675LR-M2290 900 Amp, 15/25kV, 600 Series Elbow with Insulated Plug, Cap, Stud, Lug and Cable…

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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, designed for 15kV and 25kV class systems.

Estimated time: 1h 30m

1. De-energize Apparatus and Inspect Parts

   DANGER: Ensure all apparatus are de-energized during installation or removal of parts. Do not touch or move energized products. Inspect all parts for damage, correct rating, and compatibility with mating components. Remove any protective shipping covers and replace with appropriate HV insulated caps or connectors before submerging or energizing the circuit. Check package contents and component fit, and have all required tools at hand while maintaining cleanliness.

2. Prepare Cable for Assembly

   Assemble the cable in its final position, allowing enough slack to provide adequate clearance for removing the elbows. For concentric neutral cable, unwind the neutral wires. Cut the cable 1-3/4 inches (45mm) from the centerline of the mating product.

3. Clean and Prepare Cable Outer Surface

   Clean the outer surface of the cable for a distance of 24 inches (610mm) or up to the bent-back concentric neutral wires. Then, remove the outer jacket (where applicable) and prepare the cable according to its type (e.g., non-jacketed, jacketed, Unishield, lead sheath, flat metallic tape shield, fabric tape shield, or longitudinally corrugated shield). Refer to specific instructions for grounding devices or shield adapters if those products are being used.

4. Bevel Cable Insulation and 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, 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.

5. Trim Cable Insulation and Verify Conductor Length

   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 length of the exposed conductor must be between 4-1/4 inches and 4-9/16 inches (108mm-116mm); otherwise, re-do the assembly.

6. Insert and Crimp Compression Lug

   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, re-do the assembly.

7. Lubricate and 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 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.

8. Prepare and Lubricate Mating Products

   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 already equipped with a stud. Clean and lubricate both the elbow and the mating part with the lubricant supplied, ensuring surfaces remain clean.

9. 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.

10. Connect Opposite End Mating Part (if applicable)

    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 the instructions supplied with that specific mating part. CAUTION: When constructing 600-amp L-Kits, ensure each component is tightened to the specified torque.

11. Install Insulating Plug and Cap (if used)

    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.

12. Ground the Cable Shield

    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.

13. Perform Voltage Test

    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 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 meter used. Test with a suitable sensing device, made for use with separable connectors manufactured with capacitive test points, to determine if the cable is energized. 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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