Thomas & Betts K655BLR Installation Manual

IS---0249

IS--655LR

June 2011

Page 1 of 4

Installation Instructions

655/675LR and K655/K675LR

Deadbreak Elbow Connectors

CONTENTS: Elbow, Cable Adapter, Compression Lug, Insulating Plug, Lubricant, Stud Prepack, Crimp chart,

The 655/675LR and K655/K675LR connectors are designed to: 1) provide fully shielded, fully submersible deadfront cable
connectionsto highvoltageapparatus and2)provideameans tospliceand tap600--ampere(655/K655LR) or900--ampere
(675/K675LR) systems. The connectors are rated for use on 15kV and 25kV class systems respectively.

All apparatus must be de-energized during
installation or removal of part(s). For loadbreak
products follow operating instructions. All
deadbreak connectors must be de-energized
before operating. All 200A deadbreak connectors
must be mechanically secured with bails when
connected.
All apparatus must be installed and operated in
accordance with individual user, local, and
national work rules. These instructions do not
attempt to provide for every possible
contingency.
Do not touch or move energized products.
Excess distortion of the assembled product may
result in its failure.

FOR MORE INFORMATION ON PARTS,INSTALLATION RATINGSAND COMPATIBILITY, CALLTHENEAREST ELASTIMOLDOFFICE.
WARRANTY: Thomas& Bettswarrantsthatthis productwillbefreefromdefectsinmaterialsandworkmanshipforthe periodof two (2) years from

thedate of shipment. Upon promptnotificationof any warranted defect, Thomas & Betts will, at its option, repair, replace or refund thepurchase
price. Proofof purchaseis required. Unauthorized modification or improper installation will void all warranties.
Limitations andExclusions: THE ABOVEWARRANTY IS THESOLEWARRANTY CONCERNINGTHISPRODUCT, ANDISIN LIEU OF
ALLOTHERWARRANTIES EXPRESSOR IMPLIED,INCLUDING BUTNOT LIMITEDTO ANYIMPLIED WARRANTY OFMARCHATABILITY
OR FITNESS FOR A PARTICULAR PURPOSE, WHICH ARE SPECIFICALLY DISCLAIMED. LIABILITY FOR BREACH OF THE ABOVE
WARRANTY IS LIMITED TO COST OF REPAIR OR REPLACEMENT OF THE PRODUCT, AND UNDER NO CIRCUMSTANCES WILL
THOMAS & BETTS BE LIABLE FOR ANY INDIRECT, SPECIAL,INCIDENTAL OR CONSEQUENTIAL DAMAGES.

InstallationInstructions.

DANGER

Inspect parts for damage, rating and
compatibility with mating parts.
This product should be installed only by
competent personnel trained in good safety
practices involving high voltage electrical
equipment. These instructions are not intended
as a substitute for adequate training or
experience in such safety practices.
Failure to follow these instructions will result in
damage to the product and serious or fatal injury.
If this product is supplied with a protective
shipping cover(s), remove this shipping cover(s)
and replace with the appropriate HV insulated
cap(s) or connector(s) before submerging or
energizing the circuit.

IMPORTANT

1. Checkcontentsofpackagetoensurethey arecomplete
and undamaged.

2. Check all components to ensure proper fit with cable
and/or mating products.

3. Read entire installation instructions before starting.

4. Haveallrequired toolsat handand maintaincleanliness
throughout the procedure.

GENERAL INSTRUCTIONS

STEP 1

Position the cable so it is located in the final assembled position with enough slack to provide adequate clearance for
removingtheelbows. Forconcentric neutral cable, unwind the concentricneutralwires.Cutthecable 1--3/4” (45mm)from
center line of the mating product.

1--3/4”

(45mm)

600--ampere

Concentric Neutral Wires

(Where Applicable)

STEP 2

Clean the outer surface of the cable a distance of 24” (610mm) or up to the bent back concentric neutral wires.

IS--0249
IS--655LR

June 2011
Printed in U.S.A.

8155 T&B Boulevard, Memphis, Tennessee 38125
(800) 888--0211 Fax: [phone]

Mating Product

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June 2011
Page 2 of 4

STEP 3 CABLE PREPARATION Follow the STEPS A, B or C that apply to the cable being prepared.
A.If a 20MA or 21MA grounding device or 600ECSJacket Cable Seal is being used, refer to the Installation Instructions

supplied with those products for removal of cable outer jacket, shield connection and grounding.

B.UNISHIELD* AND LEAD SHEATH CABLE

For UNISHIELD* or LEAD SHEATH cable a 10TL cable shield adapter is required. Refer to the Installation Instructions
supplied with the 10TL cable shield adapter for cable preparation.

*Unishield is a registered Trade Mark of ANACONDAWIRE and CABLE COMPANY.

C.JACKETED AND NON-JACKETED CABLE

Remove the outer jacket (where applicable) and prepare cable as shown.

1. NON-JACKETED CONCENTRIC

NEUTRAL WIRES

Semi---con Shield

Bind

Tape Marker

Cable Insulation

9---3/4”(248mm)

10---3/4”(273mm)

12---3/4”(324mm)

3. JACKETED FLAT METALLIC TAPE

SHIELD

Flat Metallic
Tape Shield

Outer
Jacket

Tape Marker

Semi---con Shield

Cable Insulation

9---3/4”(248mm)

10---3/4”(273mm)

Flat Metallic Tape Shield
and VinylTape Location

12---3/4”(324mm)

2. JACKETED SHIELD WIRES

Shield Wires

Outer
Jacket

Tape Marker

Semi---con Shield

Cable Insulation

9---3/4”(248mm)

10---3/4“(273mm)

12---3/4”(324mm)

4. JACKETED FABRIC TAPE SHIELD

Fabric Tape
Shield

Outer
Jacket

Tape Marker

Tape Retainer

Cable Insulation

9---3/4”(248mm)

10---3/4”(273mm)

12---3/4”(324mm)

5. JACKETED LONGITUDINALLY

CORRUGATED SHIELD

Tape Marker

Longitudinally

Corrugated Shield

Outer
Jacket

Flush

Semi---con Shield

Cable Insulation

9---3/4”(248mm)

10---3/4”(273mm)

12---3/4”(324mm)

STEP 4 CABLE ADAPTER

Bevelthe end of the cableinsulationata 45_angle, approximately1/4” (6mm) back.Thoroughlyclean, then lubricatecable insulation
always workingtowardsemi---con shield. Installcableadapter, smallendfirst, untilit isflushwiththeedge ofthetape marker.

Tape Marker

Edge

Cable Insulation

Clean and

Lubricate

Bevel

Cable Adapter

STEP 5 CONDUCTOR

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 exposed
conductor should be between 4---3/8” -- 4--11/16”
(111mm---119mm). Otherwise redo assembly.

Cable Adapter

4---3/8”--4--11/16”

(111mm---119mm)

Even with Cable Adapter

Bare
Conductor

STEP 6 COMPRESSION LUG

Copper Conductor: Fully insert conductor into compression Lug.
Aluminum Conductor: Wire brush conductor and immediately fully insert conductor into compression lug.

Measure the “Check Dimension” before crimping. This
dimension should be less than 6---1/2”. otherwise redo
assembly. Crimp the compression lug following the
crimpinginstructions suppliedwiththe lug.Wipeallexcess
inhibitor from compressionlugand cable adapter surface
after crimping. The distance from the end of the
compressionlugtothecable adapterafter crimpingshould
be between 6---1/2” to 7---1/4” (165mm---184mm).
Otherwise redo assembly.

Compression Lug

Cable
Adapter

Check Dimension

Before Crimping

Locate First Crimp
on this end

6---1/2” to 7---1/4”
(165mm---184mm)

After Crimping

STEP 7 ELBOW

Lubricate cable adapter and inside of elbow cable
entrance. Install elbow onto cable adapter until the elbow
can not advance further. Make sure cable adapter is still
flush with tape marker. If not, reposition cable adapter.
Remove tape marker.

Flush

Cable Adapter

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June 2011

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Tape Marker

Lubricate

STEP 8 MATING PRODUCTS

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 thethreadedstudsuppliedwith the elbow into
mating part, if the mating part is not equipped with a stud. Clean and lubricate both the elbow and the mating part with
lubricant supplied. (Keep surfaces of elbow and mating part clean.)

Clean &

Lubricate

Reducing

Tap Plug

Insulating

Plug

Threaded

Apparatus

Clean &

Lubricate

Bushing

Stud

Connector

Clean & Lubricate

Reducing

Plug

Lubricate

Tap Well

Clean &

Elbow Tap

Plug

STEP 9

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

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June 2011
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STEP 10

Clean andlubricatethe mating partfor the opposite end of
the elbow. Insert themating part into the elbow. Engage
the threads and hand tighten. Torque mating part
accordingto theinstructionssupplied withthematingpart.

Elbow

Tap Plug

Connector

Plug

Clean

&

Lubricate

Clean & Lubricate

Insulating

Clean

&

Lubricate

Basic

Plug

Reducing

Tap Plug

Reducing

Tap Well

Clean

&

Lubricate

STEP 12

Insert one end of a piece of wire with ampacity at least
equivalent to No. 14 AWG Copper through the grounding
eyeand twisttomakeasmallloop.DoNot damagetheeye.
Connect 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 nogrounding 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.

STEP 11

If an insulating plug is used as a mating part, clean and
lubricate inner surface of the voltage detection cap and
placeonelbow. Pushdown harduntil capsnaps intoplace.
Follow voltage test directions below.

Capacitive Test Point

Clean &

Lubricate

From Grounding
Device or Cable Shield

Ground Eye

Connection Wire

To Ground

STEP 13

CAUTION: When constructing600amp L--Kitsbesureto tighteneachcomponenttospecifiedtorque per instructionsprovided.

VOLTAGE TEST

The ELASTIMOLD deadbreak elbow connector is equipped with an integral capacitance test point that can be used to
establish whether or not the circuit is energized. When using the test point, complete the following steps:

1. Remove testpointcap withahotstick. When removingcap, PEELOFFATAN ANGLEratherthan pullingdirectlyin line
with the test point assembly.

2. WARNING:THEVOLTAGE TESTPOINTIS ACAPACITANCEDEVICE,IT ISNOT DIRECTLY CONNECTEDTOTHE
CONDUCTOR. Do not use conventional voltage measuring equipment. Follow the manufacturer’s directions for the
meter that is used. Test with a suitable sensing device, made for use with separable connectors manufactured with
capacitivetestpoints, todetermine ifcableisenergized.Contamination, moisture,dirt, etc. aroundthe testpoint oruse
of the wrong measuring equipment can provide a false “no voltage” indication on an energized elbow. To prevent
serious orfatal injury treat theelbow as energizeduntil the “novoltage” testpoint indication is confirmedbyother means.

3. After voltage detection has been made, clean and lubricate the inside surface of the cap with silicone grease and

replace it on the test point.