ABB Installation Products K655LR-H2290 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 the safe and proper installation of K655/K675LR Deadbreak Elbow Connectors, designed for fully shielded, fully submersible deadfront cable connections to high voltage apparatus.

Estimated time: 2h

1. De-energize Apparatus and Inspect Components

   DANGER: Ensure all apparatus in the work area are de-energized during installation or removal of part(s). Failure to follow these instructions will result in serious or fatal injury. Inspect all components for damage, proper rating, and compatibility with mating parts. Read the entire installation instructions thoroughly before proceeding.

2. Prepare Cable for Connection

   Assemble the cable in its final position with enough slack to allow 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.

3. Prepare Cable Jacket and Shield

   Remove the outer jacket (if applicable) and prepare the cable shield according to the specific cable type (e.g., non-jacketed, jacketed, Unishield, flat metallic tape, fabric tape, or longitudinally corrugated shield). Refer to specific instructions for grounding devices or cable shield adapters if used.

4. Bevel 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.

5. Prepare Conductor Length

   Remove any protruding cable insulation by cutting it even with the end of the cable adapter. Ensure the length of the exposed conductor is between 4-1/4 inches and 4-9/16 inches (108mm-116mm). If the length is outside this range, redo the assembly.

6. Crimp 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 lug. Measure the 'Check Dimension' before crimping (should be less than 6-3/8 inches). Crimp the compression lug following the supplied instructions. Wipe all excess inhibitor from the lug and cable adapter. Verify the distance from the lug end to the cable adapter is 6-3/8 inches to 7-1/8 inches (162mm-181mm) after crimping.

7. 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. Confirm the cable adapter remains flush with the tape marker; reposition if necessary. Remove the tape marker.

8. Prepare Mating Products 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 provided lubricant, ensuring surfaces remain clean.

9. Connect Elbow to Mating Part

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

10. Secure Opposite End Mating Product

    Clean and lubricate the mating part intended for the opposite end of the elbow. Insert this mating part into the elbow, engage the threads, and hand tighten. Torque the mating part to the specifications provided in its own instructions.

11. Install Insulating Plug or Capacitive Test Point Cap

    If an insulating plug is used as a mating part, clean and lubricate the inner surface of the voltage detection cap and place it firmly on the elbow until it snaps into place. Proceed to the voltage test directions.

12. Ground the Cable Shield

    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.

13. Perform Voltage Test

    WARNING: The voltage test point is a capacitance device and is not directly connected to the conductor. Contamination, moisture, 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 or fatal injury. Remove the test point cap using a hotstick, peeling it off at an angle. Use a suitable capacitive sensing device, designed for separable connectors with capacitive test points, to determine if the cable is energized. Do not use conventional voltage measuring equipment. 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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