ABB Installation Products K655LR-K0380 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 installation and wiring of K655/K675LR deadbreak elbow connectors on high voltage apparatus, including cable preparation and final assembly. Ensure all apparatus are de-energized before beginning installation.

Estimated time: 1h 30m

1. Ensure Safety and Prepare for Installation

   DANGER: All apparatus must be de-energized during installation or removal of parts. Do not touch or move energized products. Inspect all parts for damage, proper rating, and compatibility with mating parts. Read all instructions completely before starting and have all required tools at hand. Maintain cleanliness throughout the procedure.

2. Assemble Cable and Clean Outer Surface

   Assemble the cable in its final position, ensuring enough slack to remove elbows. 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 the Cable End

   Remove the outer jacket (if applicable) and prepare the cable according to the specific type (e.g., non-jacketed concentric neutral, jacketed shield wires, flat metallic tape shield, fabric tape shield, or longitudinally corrugated shield). Refer to the provided diagrams for precise dimensions for cable insulation, semi-con shield, and tape marker placement. If using a 20MA/21MA grounding device, 600ECS Jacket Cable Seal, or 10TL cable shield adapter, refer to their specific installation instructions for cable preparation.

4. Install the 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. Expose the Conductor

   Remove the protruding cable insulation by cutting it even with the end of the cable adapter. Be careful not to cut or nick the cable adapter or the conductor. The length of the exposed conductor should be between 4-1/4 inches and 4-9/16 inches (108mm-116mm). If the length is outside this range, redo the assembly.

6. Install and 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; it should be less than 6-3/8 inches. Crimp the compression lug following 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 should be between 6-3/8 inches to 7-1/8 inches (162mm-181mm). If dimensions are incorrect, redo the assembly.

7. Install the Elbow Connector

   Lubricate the cable adapter and the inside of the elbow cable entrance. Install the elbow onto the cable adapter until it cannot advance further. Ensure the cable adapter remains flush with the tape marker. If not, reposition the cable adapter. Remove the tape marker.

8. Prepare Mating Products

   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. Hand tighten the threaded stud supplied with the elbow into the mating part, if the mating part is not already equipped with a stud. Clean and lubricate both the elbow and the mating part with the supplied lubricant, ensuring surfaces remain clean.

9. Connect Elbow to First 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.

10. Connect Elbow to Second Mating Part or Insulating Plug

    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. If an insulating plug is used as a mating part, clean and lubricate the inner surface of the voltage detection cap and place it on the elbow, pushing down hard until the cap 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; follow instructions supplied with any grounding device or use an alternate method. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

12. Perform Final Torque Check

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

13. Perform Voltage Test (Optional but Recommended)

    The ELASTIMOLD deadbreak elbow connector has an integral capacitance test point. To use it, remove the test point cap with a hotstick, peeling it off at an angle. WARNING: This 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 to determine if the cable is energized. Contamination or incorrect equipment can give false readings; treat the elbow as energized until confirmed otherwise by other means. 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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