ABB Installation Products K655LR-K0330 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 detailed instructions for the safe and proper installation of K655/K675LR Deadbreak Elbow Connectors, designed for fully shielded, submersible high-voltage cable connections. Ensure all apparatus are de-energized before beginning installation.

Estimated time: 2h

1. Perform Initial Safety Checks and Part Inspection

   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. Check package contents for completeness. If supplied with protective shipping covers, remove them and replace with appropriate HV insulated caps or connectors before submerging or energizing the circuit. Have all required tools at hand and maintain cleanliness.

2. Assemble Cable and Cut to Length

   Assemble the cable in its final position, ensuring enough slack for adequate clearance to remove elbows. For 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 Cable Surface and Prepare Cable

   Clean the outer surface of the cable a distance of 24 inches (610mm) or up to the bent back concentric neutral wires. Follow the specific cable preparation steps (A, B, or C) that apply to your cable type, including removing the outer jacket (if applicable) and preparing the cable according to the provided diagrams and dimensions for cable insulation, semi-con shield, and tape marker.

4. Bevel Cable 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, 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. Trim Protruding Conductor Insulation

   Remove any protruding cable insulation by cutting it even with the end of the cable adapter. Exercise caution not to cut or nick the cable adapter or the conductor. Verify that 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 from the beginning.

6. Crimp Compression Lug onto Conductor

   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 must be less than 6-3/8 inches. Crimp the compression lug following its supplied instructions. 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 inches to 7-1/8 inches (162mm-181mm); otherwise, 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 the elbow cannot advance further. Ensure the cable adapter remains flush with the tape marker; if not, reposition the cable adapter. Once confirmed, remove the tape marker.

8. Prepare and Lubricate Mating Apparatus

   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, ensuring all surfaces remain clean. DANGER: Do not connect or disconnect mating products while energized. Do not energize while disconnected.

9. Connect Elbow to Mating Apparatus Stud

   Push the elbow onto the mating part, carefully aligning the hole in the compression lug with the stud on the mating part. Ensure a secure and proper connection.

10. Connect Opposite Mating Part to Elbow

    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 according to the specific instructions supplied with that mating part to ensure proper connection and sealing.

11. Install Insulating Plug and Cap (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 onto the elbow and push down firmly until it snaps securely into place. This step prepares for subsequent voltage testing.

12. Ground the Cable Shield

    Insert one end of a grounding wire, with an ampacity at least equivalent to No. 14 AWG Copper, through the grounding eye and twist it to form a small loop. Do not damage the grounding eye. Connect this wire to ground using a suitable connector. The cable shield must be grounded according to the instructions supplied with the grounding device, or through an alternate method if no device is used. It is also recommended to waterproof the cable jacket at this point to prevent moisture from entering the cable.

13. Perform Capacitive Voltage Test

    CAUTION: When constructing 600amp L-Kits, ensure each component is tightened to the specified torque per instructions. To test for voltage, remove the test point cap with a hotstick, peeling it off at an angle rather than pulling directly. 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 and follow its manufacturer's directions. Treat the elbow as energized until the 'no voltage' indication is confirmed by other means, as contamination or wrong equipment can give false readings. 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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