ABB Installation Products K655BLR-BIP 15/25kV 600 Series Deadbreak Elbow without Test Point Housing Only (with Stud), Basic…

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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 installation and connection of 655/675LR and K655/K675LR deadbreak elbow connectors on high voltage apparatus. It covers cable preparation, lug crimping, and final assembly.

Estimated time: 2h

1. Perform Initial Safety Checks and Inspection

   DANGER: All apparatus must be de-energized during installation or removal of parts. Do not touch or move energized products. Inspect all parts for damage, rating, and compatibility with mating parts. Verify package contents are complete and undamaged, and all components fit properly. Read all instructions before starting and maintain cleanliness throughout the procedure.

2. Position Cable and Make Initial Cut

   Assemble the cable in its final position, ensuring enough slack for elbow removal. For concentric neutral cable, unwind the concentric neutral wires. Cut the cable 1-3/4” (45mm) from the centerline of the mating product.

3. Clean and Prepare Cable

   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 cable preparation instructions for your cable type (e.g., 20MA/21MA grounding device, UNISHIELD, Jacketed, or Non-Jacketed cable) to remove the outer jacket (if applicable) and expose the cable insulation, semi-con shield, and shield wires/tape to the specified dimensions. Create a tape marker.

4. Install Cable Adapter

   Bevel the end of the cable insulation at a 45-degree angle, approximately 1/4” (6mm) back. Thoroughly clean, 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. Prepare 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. Ensure the length of the exposed conductor is between 4-1/4” – 4-9/16” (108mm-116mm). If the length is incorrect, redo the assembly.

6. 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. Measure the 'Check Dimension' before crimping; it must be less than 6-3/8”. Crimp the compression lug following the instructions supplied with the lug. Wipe all excess inhibitor from the lug and cable adapter surface after crimping. Verify the distance from the end of the compression lug to the cable adapter is between 6-3/8” to 7-1/8” (162mm-181mm) after crimping. If incorrect, redo the assembly.

7. Install Elbow Connector

   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; reposition if necessary. Remove the tape marker.

8. Prepare Mating Products for Connection

   DANGER: DO NOT CONNECT OR DISCONNECT MATING PRODUCTS WHILE ENERGIZED. DO NOT ENERGIZED WHILE DISCONNECTED. Remove protective caps from 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, keeping surfaces 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 Mating Product

    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.

11. 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 hard until it snaps into place.

12. 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 make a small loop; do not damage the eye. Connect this wire to ground using a suitable connector. Ground the cable shield according to the instructions supplied with the grounding device, or through an alternate method if no grounding device is used. Waterproof the cable jacket at this point to prevent moisture from entering the cable.

13. Perform Voltage Test

    Remove the test point cap with a hotstick, peeling off at an angle rather than pulling directly. WARNING: The voltage test point is a capacitance device, not directly connected to the conductor. Do not use conventional voltage measuring equipment. Use a suitable sensing device, made for separable connectors with capacitive test points, to determine if the cable is energized. Treat the elbow as energized until the '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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