ABB Installation Products K655LR-F2250 600 Series Elbow with insulated plug, cap, stud, lug and cable adapter, 15/25KV, 600…

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How to Install K655LR/K675LR Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe and proper installation of K655LR/K675LR Deadbreak Elbow Connectors, including cable preparation, lug crimping, and connection to high voltage apparatus.

Estimated time: 2h

1. Ensure Safety and Prepare Components

   DANGER: All apparatus must be de-energized during installation or removal of parts. This product should be installed only by competent personnel trained in good safety practices involving high voltage electrical equipment. 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 proper fit with cable and/or mating products. Have all required tools at hand and maintain cleanliness throughout the procedure.

2. Assemble Cable and Make Initial Cut

   Assemble the cable in its final position with 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 inches (45mm) from the center line of the mating product.

3. Clean and Prepare Cable for Termination

   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 installation instructions and diagrams supplied with the product for specific cable preparation steps based on your cable type (e.g., non-jacketed, jacketed, Unishield, lead sheath). Remove the outer jacket (where applicable) and prepare the cable shield and insulation according to the specified dimensions.

4. 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, 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 for Lug

   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 inches and 4-9/16 inches (108mm-116mm). If the length is outside this range, redo the assembly.

6. Install 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 6-3/8 inches. 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 between 6-3/8 inches to 7-1/8 inches (162mm-181mm). If dimensions are incorrect, redo the assembly.

7. Install Elbow onto Cable Adapter

   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 remains flush with the tape marker; if not, reposition the cable adapter. Remove the tape marker.

8. Prepare Mating Products for Connection

   Remove protective caps from both 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. Keep all surfaces clean during this process. WARNING: DO NOT CONNECT OR DISCONNECT MATING PRODUCTS WHILE ENERGIZED. DO NOT ENERGIZE WHILE DISCONNECTED.

9. Connect Elbow to First 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 Second Mating Part (if applicable)

    Clean and lubricate the mating part for the opposite end of the elbow. Insert this 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 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 hard until it snaps into place. Prepare to follow the voltage test directions.

12. Ground the Cable Shield

    Insert one end of a grounding 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 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.

13. Torque All Components (for 600A L-Kits)

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

14. Perform Voltage Test

    To determine if the circuit is energized, remove the test point cap with a hotstick, peeling it off at an angle. 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 and follow its manufacturer's directions. Contamination or incorrect equipment can give 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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