ABB Installation Products K655LR-K0320-S 600 Amp, 15/25kV, 600 Series Deadbreak, Elbow with Insulated Plug, Cap, Stud, Lug and…

Frequently Asked Questions

How to Install K655/K675LR Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe and proper installation of 600-ampere K655/K675LR Deadbreak Elbow Connectors on 15kV and 25kV class systems.

Estimated time: 1h 30m

1. Ensure Safety and Prepare Components

   DANGER: De-energize all apparatus before beginning installation. This product must be installed only by competent personnel trained in high voltage safety practices. Inspect all package contents and components for completeness, damage, proper rating, and compatibility with mating parts. 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 with 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 24 inches (610mm) or up to the bent-back concentric neutral wires. Follow the specific cable preparation instructions (e.g., jacket removal, shield preparation) as detailed in the document for your cable type (non-jacketed, jacketed, Unishield, lead sheath, etc.).

3. Install Cable Adapter and Prepare Conductor

   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. Remove the protruding cable insulation by cutting it even with the end of the cable adapter, ensuring not to nick the cable adapter or conductor. The exposed conductor length must be between 4-1/4 inches and 4-9/16 inches (108mm-116mm); if not, redo the assembly.

4. 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 lug. Measure the 'Check Dimension' before crimping; it must be less than 6-3/8 inches. Crimp the compression lug according to the instructions supplied with the lug. Wipe all excess inhibitor from the lug and cable adapter surface after crimping. The distance from the end of the compression lug to the cable adapter after crimping must be between 6-3/8 inches to 7-1/8 inches (162mm-181mm); if not, redo the assembly.

5. Install the Elbow Connector

   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. Verify the cable adapter is still flush with the tape marker; if not, reposition it. Remove the tape marker.

6. Connect to Mating Apparatus

   WARNING: DO NOT CONNECT OR DISCONNECT MATING PRODUCTS WHILE ENERGIZED. DO NOT ENERGIZE WHILE DISCONNECTED. Remove any protective shipping 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 the mating part. Clean and lubricate both the elbow and the mating part with the supplied lubricant. Push the elbow onto the mating part, aligning the hole in the compression lug with the stud on the mating part.

7. Connect Opposite End and Torque

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

8. 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 hard until it snaps into place.

9. Ground the Cable Shield and Waterproof

   Insert one end of a piece of wire (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 a grounding device if used, or an alternate method. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

10. Perform Voltage Test

    The ELASTIMOLD deadbreak elbow connector has an integral capacitance test point. To use it: 1. Remove the test point cap with a hotstick, peeling it off at an angle. 2. 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 made for capacitive test points, following its manufacturer's directions. Treat the elbow as energized until the 'no voltage' indication is confirmed by other means, as contamination or incorrect equipment can give false readings. 3. 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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