ABB Installation Products K655LR-K0320 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, including cable preparation, lug crimping, and connection to mating apparatus for 15kV and 25kV class systems.

Estimated time: 1h 30m

1. Ensure Safety and Prepare Workspace

   DANGER: All apparatus must be de-energized during installation or removal of parts. Do not touch or move energized products in the work area. This product should be installed only by competent personnel trained in good safety practices involving high voltage electrical equipment. Gather all required tools and supplies, ensuring cleanliness throughout the procedure. Inspect all components for damage, proper rating, and compatibility with mating parts.

2. Prepare the Cable for Connection

   Assemble the cable in its final position with enough slack to provide adequate clearance for removing the elbows. For concentric neutral cable, unwind the concentric neutral wires. Cut the cable 1-3/4” (45mm) from the centerline of the mating product. Clean the outer surface of the cable for a distance of 24” (610mm) or up to the bent-back concentric neutral wires. Remove the outer jacket (where applicable) and prepare the cable insulation and semi-con shield according to the specific cable type and provided diagrams, ensuring proper tape marker placement.

3. Install the Cable Adapter

   Bevel the end of the cable insulation at a 45-degree angle, approximately 1/4” (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.

4. Prepare the Conductor

   Carefully 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 length of the exposed conductor is between 4-1/4” and 4-9/16” (108mm-116mm); if not, re-do 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 and immediately fully insert it into the compression lug. Measure the “Check Dimension” before crimping; this dimension should be less than 6-3/8”. 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. Verify the distance from the end of the compression lug to the cable adapter after crimping is between 6-3/8” to 7-1/8” (162mm-181mm); if not, re-do 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 until it cannot advance further. Make sure the cable adapter is still flush with the tape marker; if not, reposition the cable adapter. Remove the tape marker.

7. 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 is not equipped with a stud, hand tighten the threaded stud (supplied with the elbow) into it. Clean and lubricate both the elbow and the mating part with the lubricant supplied, keeping surfaces clean.

8. Secure the Elbow to the 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.

9. Connect the Opposite Mating Part (if applicable)

   Clean and lubricate the mating part for the opposite end of the elbow. Insert the 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.

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 on the elbow and push down hard until it snaps into place.

11. Ground the Cable Shield

    Insert one end of a piece of 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; ground according to the instructions supplied with the grounding device, or through an alternate method if no grounding device is used. It is also recommended that the jacket of the cable be waterproofed at this point to prevent moisture from entering the cable.

12. Torque Components for 600amp L-Kits (Caution)

    CAUTION: When constructing 600amp L-Kits, be sure to tighten each component to the specified torque per the instructions provided with those components.

13. Perform Voltage Test

    WARNING: The voltage test point is a capacitance device and is not directly connected to the conductor. Do not use conventional voltage measuring equipment. Remove the test point cap with a hotstick, peeling it off at an angle rather than pulling directly in line. Test with a suitable sensing device, made for use with separable connectors manufactured with capacitive test points, to determine if the cable is energized. Contamination, moisture, dirt, or using the wrong measuring equipment can provide a false “no voltage” indication. To prevent serious or fatal injury, treat the elbow as energized until the “no voltage” test point indication is confirmed by other means. After voltage detection, clean and lubricate the inside surface of the cap with silicone lubricant and replace it on the test point.

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