ABB Installation Products K655LR-F0240 600 Amp, 15/25kV, 600 Series Deadbreak, Elbow with Insulated Plug, Cap, Stud, Lug and…

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How to Install K655/K675LR Deadbreak Elbow Connectors

This guide provides step-by-step instructions for installing 655/675LR and K655/K675LR Deadbreak Elbow Connectors, designed for fully shielded, submersible cable connections to high voltage apparatus on 15kV and 25kV class systems. Ensure all safety precautions are followed.

Estimated time: 2h

1. Prepare for Installation and De-energize Apparatus

   DANGER: All apparatus must be de-energized during installation or removal of parts. Do not touch or move energized products. Ensure competent personnel trained in high voltage electrical equipment perform this installation. Inspect all parts for damage, proper rating, and compatibility with mating components. Check package contents for completeness. Have all required tools at hand and maintain cleanliness throughout the procedure.

2. Prepare the Cable for Connection

   Assemble the cable in its final position, ensuring enough slack for elbow removal. For concentric neutral cable, unwind the neutral wires. Cut the cable 1-3/4 inches (45mm) from the centerline of the mating product. Clean the outer surface of the cable for a distance of 24 inches (610mm) or up to the bent-back concentric neutral wires. Refer to the specific cable preparation diagrams (A, B, or C) in the product documentation for detailed instructions on removing the outer jacket, shield connection, and grounding based on your cable type (e.g., UNISHIELD, jacketed, non-jacketed).

3. Bevel Cable Insulation and Install Cable Adapter

   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 towards the semi-con shield. Install the cable adapter, small end first, until it is flush with the edge of the tape marker.

4. Trim Conductor Insulation

   Remove any protruding cable insulation by cutting it even with the end of the cable adapter. Exercise caution not to cut or nick the cable adapter or the conductor. Verify the length of the exposed conductor is between 4-1/4 inches and 4-9/16 inches (108mm-116mm). If the length is incorrect, redo the assembly.

5. Crimp the Compression Lug

   For copper conductors, fully insert the conductor into the compression lug. For aluminum conductors, wire brush the conductor immediately before fully inserting it into the compression lug. Measure the 'Check Dimension' before crimping; it must be less than 6-3/8 inches. Crimp the compression lug according to the instructions provided with the lug. After crimping, wipe off any excess inhibitor from the compression lug and cable adapter surface. The distance from the end of the compression lug to the cable adapter should be between 6-3/8 inches and 7-1/8 inches (162mm-181mm). If dimensions are incorrect, redo the assembly.

6. Install the Elbow onto the Cable Adapter

   Lubricate the cable adapter and the inside of the elbow's cable entrance. Install the elbow onto the cable adapter, pushing until it cannot advance further. Confirm that the cable adapter remains flush with the tape marker; reposition if necessary. Remove the tape marker.

7. Prepare Mating Product and Elbow for Connection

   DANGER: DO NOT CONNECT OR DISCONNECT MATING PRODUCTS WHILE ENERGIZED. DO NOT ENERGIZE WHILE DISCONNECTED. Remove any protective caps from both the elbow and the mating part. If the mating part lacks 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 all surfaces remain clean.

8. Connect Elbow to Mating Product

   Push the elbow onto the mating part, carefully aligning the hole in the compression lug with the stud on the mating part.

9. Connect Opposite End of Elbow (if applicable)

   If connecting to another mating product on the opposite end of the elbow, clean and lubricate that mating part. Insert the mating part into the elbow, engage the threads, and hand-tighten. Torque the mating part to the specifications provided in its instructions.

10. Install Insulating Plug (if used)

    If an insulating plug is used as a mating part, clean and lubricate the inner surface of the voltage detection cap. Place the cap onto the elbow and push down firmly until it snaps into place.

11. Ground the Cable Shield

    Insert one end of a grounding wire (at least 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 cable shield must be grounded; follow instructions supplied with your grounding device or use an alternate method if no device is used. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

12. Torque L-Kit Components (if applicable)

    CAUTION: When constructing 600-amp L-Kits, ensure each component is tightened to its specified torque according to the instructions provided with the kit.

13. Perform Voltage Test

    Remove the test point cap using a hotstick, peeling it 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 designed for capacitive test points, following the manufacturer's directions, to determine if the cable is energized. Contamination, moisture, or incorrect equipment can cause a false 'no voltage' indication. Treat the elbow as energized until the 'no voltage' indication is confirmed by other means to prevent serious 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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