ABB Installation Products K655LR-H0220 600 Amp, 15/25 kV, 600 Series Deadbreak, Elbow with Insulated Plug, Cap, Stud, Lug and…

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How to Install K655LR Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe installation and preparation of K655LR Deadbreak Elbow Connectors for high voltage systems. Ensure all apparatus are de-energized before beginning any work.

Estimated time: 2h

1. De-energize and Inspect Apparatus

   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, proper 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.

2. Assemble and Cut Cable

   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 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

   Prepare the cable according to its specific type (e.g., Unishield, Lead Sheath, Jacketed, Non-Jacketed) and the provided diagrams. Remove the outer jacket where applicable. Refer to separate instructions for 20MA/21MA grounding devices, 600ECS Jacket Cable Seals, or 10TL cable shield adapters if used.

5. 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.

6. Expose 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. Verify the exposed conductor length is between 4-1/4 inches and 4-9/16 inches (108mm-116mm); otherwise, redo the assembly.

7. 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 (must be less than 6-3/8 inches). Crimp the compression lug following its supplied instructions. Wipe all excess inhibitor from the lug and cable adapter. Verify the distance from the end of the compression lug to the cable adapter is between 6-3/8 inches and 7-1/8 inches (162mm-181mm) after crimping; otherwise, redo the assembly.

8. Install Elbow onto Cable Adapter

   Lubricate the cable adapter and the inside of the elbow's 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.

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 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 surfaces remain clean.

10. Connect Elbow to Mating Part

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

11. Connect Opposite End of Elbow

    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 its supplied instructions.

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 firmly until it snaps into place.

13. Ground Cable Shield and Waterproof Jacket

    Insert one end of a No. 14 AWG Copper wire (or equivalent ampacity) 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 either via a grounding device (following its instructions) or an alternate method. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

14. Perform Final Torque Check (for L-Kits)

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

15. Remove Voltage Test Point Cap

    Remove the test point cap using a hotstick. Peel off the cap at an angle rather than pulling directly in line with the test point assembly.

16. Test for Voltage

    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. Test with a suitable sensing device designed for separable connectors with capacitive test points to determine if the cable is energized. Contamination, moisture, dirt, 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 or fatal injury.

17. Replace Voltage Test Point Cap

    After voltage detection has been made, clean and lubricate the inside surface of the cap with silicone lubricant and replace it securely on the test point.

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