ABB Installation Products K655LR-LM0330-S 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 series 600-ampere and 900-ampere deadbreak elbow connectors on 15kV and 25kV class systems. It covers cable preparation, connector assembly, grounding, and final voltage testing.

Estimated time: 1h 30m

1. Ensure Safety and Inspect Components

   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. If the product is supplied with protective shipping covers, remove them and replace with appropriate HV insulated caps or connectors before submerging or energizing the circuit.

2. Position and Cut the Cable

   Assemble the cable in its final position, ensuring enough slack for elbow removal. For 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 and Prepare the Cable

   Clean the outer surface of the cable for a distance of 24 inches (610mm) or up to the bent-back concentric neutral wires. Remove the outer jacket (if applicable) and prepare the cable insulation and semi-con shield according to the specific cable type dimensions provided in the documentation, using tape markers for accuracy.

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, working towards the semi-con shield. Install the cable adapter, small end first, until it is flush with the edge of the tape marker.

5. Prepare the Conductor

   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 inches and 4-9/16 inches (108mm-116mm); otherwise, redo the assembly.

6. Install 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 (must be less than 6-3/8 inches). Crimp the compression lug according to its supplied instructions. Wipe all excess inhibitor from the lug and cable adapter. Verify the distance from the end of the lug to the cable adapter is between 6-3/8 inches to 7-1/8 inches (162mm-181mm) after crimping.

7. Install the Elbow

   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. Ensure the cable adapter remains flush with the tape marker; reposition if necessary. 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 it 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 the Elbow to the Mating Part

   Push the elbow onto the mating part, carefully aligning the hole in the compression lug with the stud on the mating part.

10. Connect the Opposite Mating Part (if applicable)

    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 instructions supplied with that specific mating part. CAUTION: Ensure each component is tightened to its specified torque.

11. 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 firmly until it snaps into place. Proceed to the voltage test.

12. Ground the Cable Shield

    Insert one end of a No. 14 AWG Copper wire (or equivalent ampacity) through the grounding eye and twist to form 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 for any grounding device used, or ground via an alternate method. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

13. Perform Voltage Test

    Remove the test point cap with 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 to determine if the cable is energized. 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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