ABB Installation Products K655CCP-M0380 15/25kV, 600 Amp, no test point, Combo T Connecting Plug with Stud, Cable Adapter and…

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How to Install K655/K656CCP Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe and proper installation of K655/K656CCP Deadbreak Elbow Connectors on 15kV or 25kV class systems, including cable preparation, lug crimping, and connection to mating apparatus.

Estimated time: 2h

1. Prepare for Installation and Safety Check

   Review the contents of the package to ensure all parts are complete and undamaged. Inspect all components for proper fit with the cable and/or mating products. Ensure all apparatus are de-energized during installation or removal of parts to prevent serious or fatal injury. Have all required tools at hand and maintain cleanliness throughout the procedure.

2. Position and Cut Cable

   Position the cable in its final assembled location, allowing enough slack for adequate clearance to remove the elbows. For concentric neutral cable, unwind the concentric neutral wires. Cut the cable 1-3/4 inches (45mm) from the centerline of the mating product.

3. Clean Cable Outer Surface

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

4. Prepare Cable Jacket and Shield

   Follow the instructions that apply to your specific cable type for removing the outer jacket and preparing the shield. This may involve removing the outer jacket to 12-3/4 inches (324mm), folding back shield wires, removing flat metallic tape shield and securing with vinyl plastic tape, or removing fabric/corrugated shields and installing tape retainers/markers. For UNISHIELD* or lead sheath cables, refer to the 10TL cable shield adapter instructions.

5. Prepare Semi-Con Shield and Cable Insulation

   Remove the semi-con shield to the dimensions shown (9-3/4 inches or 248mm, and 10-3/4 inches or 273mm), ensuring not to cut or nick the cable insulation. Bevel the end of the cable insulation at a 45-degree angle, approximately 1/4 inch (6mm) back.

6. Clean, Lubricate, and Install Cable Adapter

   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.

7. Trim Insulation and Verify Conductor Length

   Remove any 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 4-3/8 inches to 4-11/16 inches (111mm-119mm). If the length is incorrect, redo the assembly.

8. Prepare Conductor and 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 into the compression lug. Measure the 'Check Dimension' before crimping (it should be less than 6-1/2 inches or 165mm). 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 6-1/2 inches to 7-1/4 inches (165mm-184mm); otherwise, redo the assembly.

9. Lubricate and Install 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. If not, reposition the cable adapter. Remove the tape marker.

10. Prepare 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. Install the stud in the mating part. Clean and lubricate both the elbow and the mating part with the lubricant supplied, ensuring surfaces remain clean.

11. Connect Elbow to Mating Part

    Push the elbow onto the mating part. Using the 600 ATM assembly tool, thread the connector into the mating part until it bottoms. Apply 50 to 60 foot-pounds of torque.

12. Ground the Connector and 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 according to the instructions supplied with any grounding device, or through an alternate method if no device is used. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

13. Install Additional Mating Connectors (Optional)

    If applicable, clean and lubricate the entire male interface and either a DR(G), GLR, or LR connector of the appropriate voltage class with the supplied or ELASTIMOLD® approved lubricant. Install the DR(G), GLR, or LR to the bushing interface following the instructions supplied with those specific products.

14. Perform Voltage Test (K656CCP Only)

    For K656CCP connectors, remove the test point cap with a hotstick, peeling it off at an angle. 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 meter used. Test with a suitable sensing device designed for capacitive test points to determine if the cable is energized. Contamination, moisture, or incorrect equipment can give a false 'no voltage' indication; treat the elbow as energized until confirmed by other means. After testing, clean, lubricate the inside surface of the cap with silicone grease, and replace it on the test point.

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