ABB Installation Products 655LRTPFB-N5410 600 Amp, 15kV, Deadbreak Stick-Op Connector Kit, Cable Insulation Diameter 0.675 inch to…

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 655/675LR and K655/K675LR deadbreak elbow connectors, including cable preparation, component assembly, and grounding procedures for high voltage systems.

Estimated time: 1h 30m

1. De-energize Apparatus and Inspect Components

   DANGER: Ensure all apparatus is de-energized during installation or removal of parts. Do not touch or move energized products in the work area. Inspect all package contents to ensure they are complete and undamaged. Verify all components for proper fit with the cable and/or mating products. 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” (45mm) from the centerline of the mating product. Clean the outer surface of the cable for a distance of 24” (610mm) or up to the bent back concentric neutral wires. Follow the specific instructions for your cable type (e.g., 20MA/21MA grounding device, 600ECS Jacket Cable Seal, UNISHIELD*/LEAD SHEATH with 10TL adapter, or JACKETED/NON-JACKETED cable). Remove the outer jacket (if applicable) and prepare the cable insulation and semi-con shield to the specified dimensions (e.g., 9-3/4”, 10-3/4”, 12-3/4” from the tape marker, as per cable type diagrams). Bevel the end of the cable insulation at a 45-degree angle, approximately 1/4” (6mm) back.

3. Install Cable Adapter and Compression Lug

   Thoroughly clean and 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. Remove any protruding cable insulation by cutting it even with the end of the cable adapter, ensuring not to cut or nick the adapter or conductor. The exposed conductor length must be between 4-1/4” to 4-9/16” (108mm-116mm); otherwise, redo the assembly. For copper conductors, fully insert into the compression lug. For aluminum conductors, wire brush the conductor and immediately fully insert into the compression lug. Measure the 'Check Dimension' before crimping (this dimension must be less than 6-3/8”); otherwise, redo the assembly. Crimp the compression lug according to its supplied instructions. Wipe all excess inhibitor from the lug and cable adapter surface. The distance from the end of the compression lug to the cable adapter after crimping must be between 6-3/8” to 7-1/8” (162mm-181mm); otherwise, redo the assembly.

4. Install the Elbow and Connect Mating Products

   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, ensuring the cable adapter remains flush with the tape marker. Reposition the cable adapter if necessary, then remove the tape marker. DANGER: Do not connect or disconnect mating products while energized, and do not energize while disconnected. Remove protective caps from both the elbow and the mating part. Hand tighten the threaded stud (if supplied with the elbow) into the mating part if it's not already equipped. Clean and lubricate both the elbow and the mating part with the supplied lubricant, keeping surfaces 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, then insert it into the elbow. Engage the threads, hand tighten, and torque the mating part according to its supplied instructions. 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, pushing until it snaps into place.

5. Ground the Cable Shield

   Insert one end of a wire with ampacity 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 shield of the cable must be grounded; follow instructions supplied with a grounding device, or use an alternate method if no device is present. It is also recommended to waterproof the cable jacket at this point to prevent moisture from entering the cable. CAUTION: When constructing 600amp L-Kits, ensure each component is tightened to the specified torque per instructions provided.

6. Perform Voltage Test

   Remove the test point cap with a hotstick, peeling it off at an angle rather than pulling directly in line with the 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. Use a suitable sensing device designed for separable connectors manufactured with capacitive test points to determine if the cable is energized, following the meter manufacturer's directions. Contamination, moisture, dirt, or using 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, clean and lubricate the inside surface of the cap with silicone lubricant and replace it on the test point.

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