ABB Installation Products 655LRTP-K0320 600 Amp, 15KV, Stick Op Connector Kit, Fixed Bolt, Insulating Cap, Stick Op Load Break…

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How to Install 655/675LR and K655/K675LR Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe and proper installation of 600-ampere or 900-ampere deadbreak elbow connectors on 15kV and 25kV class systems. Ensure all apparatus are de-energized before beginning installation.

Estimated time: 1h 30m

1. De-energize Apparatus and Prepare Cable

   DANGER: All apparatus must be de-energized during installation or removal of parts. Assemble the cable in its final position with enough slack for elbow removal. 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 a distance of 24 inches (610mm) or up to the bent back concentric neutral wires.

2. Prepare Cable End

   Remove the outer jacket (if applicable) and prepare the cable according to the specific cable type (e.g., non-jacketed concentric neutral, jacketed shield wires, flat metallic tape shield, fabric tape shield, or longitudinally corrugated shield) as shown in the product documentation, ensuring correct lengths for insulation, semi-con shield, and tape marker. 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 toward the semi-con shield.

3. Install Cable Adapter and Prepare Conductor

   Install the cable adapter, small end first, until it is flush with the edge of the tape marker. 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 should be between 4-1/4 inches and 4-9/16 inches (108mm-116mm). If not, redo the assembly.

4. Install 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; it 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). If not, redo the assembly.

5. Install Elbow and Prepare Mating Parts

   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 is still flush with the tape marker; if not, reposition the cable adapter. Remove the tape marker. 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 already equipped with a stud. Clean and lubricate both the elbow and the mating part with the supplied lubricant, keeping surfaces clean.

6. Connect Elbow to Mating Parts

   WARNING: Do not connect or disconnect mating products while energized. Do not energize while disconnected. Push the elbow onto the mating part, lining up 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 part. CAUTION: When constructing 600-amp L-Kits, ensure each component is tightened to the specified torque per instructions provided.

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

   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 according to the instructions supplied with the grounding device or by an alternate method if no device is used. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

8. Perform Voltage Test

   Remove the test point cap with a hotstick, peeling it off at an angle rather than pulling directly. 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, made for use with separable connectors manufactured with capacitive test points, to determine if the cable is energized. Contamination, moisture, dirt, or incorrect equipment can provide a false 'no voltage' indication. Treat the elbow as energized until the 'no voltage' test point indication is confirmed by other means to prevent serious or fatal injury. 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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