ABB Installation Products K655BLR-H0280 15/25kV 600 Series Deadbreak Elbow without Test Point (with Stud), Cable Insulation…

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How to Install K655/K675LR Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe installation, wiring, and initial setup of K655/K675LR and 655/675LR Deadbreak Elbow Connectors, designed for high voltage systems.

Estimated time: 1h 30m

1. Perform Pre-Installation Checks and Safety Procedures

   DANGER: De-energize all apparatus in the work area before installation or removal. Do not touch or move energized products. This product must be installed only by competent personnel trained in high voltage electrical equipment safety practices. Follow all individual user, local, national work rules, and electrical standards. De-energize all deadbreak connectors before operating. Inspect all parts for damage, rating, and compatibility with mating parts. Remove any protective shipping covers and replace with appropriate HV insulated caps or connectors before submerging or energizing the circuit. Check package contents for completeness and ensure all components fit properly with the cable and/or mating products. Read all instructions completely before starting and have all required tools at hand, maintaining cleanliness throughout the procedure.

2. Prepare the Cable for Installation

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

3. Clean the Cable Outer Surface

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

4. Prepare the Cable End

   Refer to specific instructions for 20MA/21MA grounding devices, 600ECS Jacket Cable Seals, UNISHIELD*/LEAD SHEATH cable (which requires a 10TL cable shield adapter), or JACKETED/NON-JACKETED cable. For JACKETED/NON-JACKETED cable, remove the outer jacket (if applicable) and prepare the cable end to the specified dimensions (e.g., 9-3/4”, 10-3/4”, 12-3/4” for insulation, semi-con shield, and tape marker respectively, from the mating product end).

5. Install the Cable Adapter

   Bevel the end of the cable insulation at a 45-degree angle, approximately 1/4” (6mm) back. Thoroughly clean and then lubricate the cable insulation, always working towards the semi-con shield. Install the cable adapter, small end first, until it is flush with the edge of the tape marker.

6. Prepare the 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 the exposed conductor must be between 4-1/4” – 4-9/16” (108mm-116mm). If the length is outside this range, redo the assembly.

7. Crimp the 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 must be less than 6-3/8”. If not, redo the assembly. 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 must be between 6-3/8” to 7-1/8” (162mm-181mm). If not, redo the assembly.

8. Install the Elbow

   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.

9. Prepare Mating Products

   DANGER: Do not connect or disconnect mating products while energized. Do not energize 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, ensuring surfaces remain clean.

10. Connect the Elbow to the 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.

11. Connect the Opposite Mating Part

    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.

12. 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 securely into place.

13. 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, 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 it according to the instructions supplied with the grounding device. If no grounding device is used, ground the shield through an alternate approved method. It is also recommended to waterproof the cable jacket at this point to prevent moisture from entering the cable.

14. Perform Voltage Test

    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. 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. Test with a suitable sensing device, specifically designed for separable connectors with capacitive test points, to determine if the cable is energized. 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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