ABB Installation Products K655LR-K0350 600 Amp, 15/25kV, 600 Series Deadbreak, Elbow with Insulated Plug, Cap, Stud, Lug and…

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How to Install K655LR/K675LR Deadbreak Elbow Connectors

This guide provides step-by-step instructions for installing K655LR/K675LR Deadbreak Elbow Connectors, designed for fully shielded, submersible cable connections to high voltage apparatus in 15kV and 25kV class systems.

Estimated time: 1h 30m

1. De-energize Apparatus and Inspect Parts

   DANGER: All apparatus must be de-energized during installation or removal of parts. Do not touch or move energized products in the work area. Inspect all parts for damage, proper rating, and compatibility with mating parts. Ensure all components are complete and undamaged.

2. Position Cable and Cut

   Assemble the cable in its final position, ensuring enough slack for elbow removal. If using 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 for Connector

   Remove the outer jacket (if applicable) and prepare the cable by removing the semi-con shield and insulation to the specified dimensions. Apply a tape marker at 12-3/4 inches (324mm) from the cable end, ensuring the semi-con shield ends at 10-3/4 inches (273mm) and the cable insulation starts at 9-3/4 inches (248mm) from the end.

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. Prepare Conductor Length

   Remove any 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. The exposed conductor length must be between 4-1/4 inches and 4-9/16 inches (108mm-116mm). If not, 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 lug. Measure the 'Check Dimension' before crimping; it should be less than 6-3/8 inches. Crimp the lug according to its supplied instructions. Wipe off any excess inhibitor from the lug and cable adapter. After crimping, the distance from the end of the lug to the cable adapter should be between 6-3/8 inches and 7-1/8 inches (162mm-181mm). If not, 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. Verify that the cable adapter remains flush with the tape marker; reposition if necessary. Remove the tape marker.

9. Prepare Mating Products for Connection

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

10. Connect Elbow to 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.

11. Connect Opposite Mating Product (if applicable)

    If connecting to the opposite end of the elbow, clean and lubricate that mating part. Insert the mating part into the elbow, engage the threads, and hand tighten. Torque the mating part according to its specific instructions.

12. 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 onto 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, twisting to form a small loop without damaging the eye. Connect this wire to ground using a suitable connector. The cable shield must be grounded either via a grounding device or an alternate method. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

14. Torque Components (for L-Kits)

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

15. Perform Voltage Test

    Remove the test point cap using a hotstick, peeling it off at an angle. 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 designed for capacitive test points. Contamination 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 injury. 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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