ABB Installation Products K655LR-LM0380 600 Amp, 15/25kV, 600 Series Deadbreak, Elbow with Insulated Plug, Cap, Stud, Lug and…

How to Install K655/K675LR Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe installation and wiring of K655/K675LR and 655/675LR Deadbreak Elbow Connectors for high voltage apparatus. Ensure all safety precautions are followed.

Estimated time: 1h 30m

1. Prepare for Installation and Safety Check

   DANGER: All apparatus must be de-energized during installation or removal. Do not touch or move energized products. This product must be installed only by competent personnel trained in high voltage electrical equipment. Inspect all parts for damage, rating, and compatibility. Check package contents for completeness. Gather all required tools and maintain cleanliness.

2. Prepare Cable Position

   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” (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” (610mm) or up to the bent back concentric neutral wires.

4. Perform Cable Preparation

   Remove the outer jacket (if applicable) and prepare the cable as shown in the diagrams, ensuring correct dimensions for insulation, semi-con shield, and tape marker placement. Refer to specific instructions for 20MA/21MA grounding devices, 600ECS Jacket Cable Seals, UNISHIELD, LEAD SHEATH, or 10TL cable shield adapters if used.

5. Bevel Insulation and Install Cable Adapter

   Bevel the end of the cable insulation at a 45-degree angle, approximately 1/4” (6mm) back. Thoroughly clean and then lubricate the cable insulation, working toward the semi-con shield. Install the cable adapter, small end first, until it is flush with the edge of the tape marker.

6. Trim Cable Insulation

   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. The length of the exposed conductor must be between 4-1/4” and 4-9/16” (108mm-116mm). If not, redo the assembly.

7. Install and 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. Measure the 'Check Dimension' before crimping (must be less than 6-3/8”). Crimp the compression lug following its supplied instructions. Wipe all excess inhibitor. Verify the distance from the lug end to the cable adapter after crimping is 6-3/8” to 7-1/8” (162mm-181mm). If not, redo the assembly.

8. 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 it cannot advance further. Ensure the cable adapter remains flush with the tape marker. If not, reposition the cable adapter. Remove the tape marker.

9. Prepare Mating Product

   WARNING: Do not connect or disconnect mating products while energized. Do not energize while disconnected. Remove protective caps from the elbow and the mating part. Hand tighten the supplied threaded stud into the mating part if it is not already equipped with one. Clean and lubricate both the elbow and the mating part with the supplied lubricant, keeping surfaces 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 Part (if applicable)

    Clean and lubricate the mating part for the opposite end of the elbow. Insert the mating part into the elbow. Engage the threads and hand tighten. Torque the mating part according to its supplied instructions. CAUTION: When constructing 600amp L-Kits, tighten each component to specified torque.

12. Install Insulating Plug 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 it on the elbow and push down hard until the cap snaps into place.

13. Ground the Cable Shield

    Insert one end of a wire (at least No. 14 AWG Copper ampacity) through the grounding eye and twist to form a small loop; do not damage the eye. Connect this wire to ground using a suitable connector. The cable shield must be grounded according to grounding device instructions or an alternate method. Waterproof the cable jacket to prevent moisture entry.

14. Remove Voltage Test Point Cap

    Using a hotstick, remove the test point cap. PEEL OFF AT AN ANGLE rather than pulling directly in line with the test point assembly.

15. Perform Voltage Test

    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, following its manufacturer’s directions, to determine if the cable is energized. Contamination or incorrect equipment can give a false 'no voltage' indication. Treat the elbow as energized until 'no voltage' is confirmed by other means to prevent serious injury.

16. Replace Voltage Test Point Cap

    After voltage detection, clean and lubricate the inside surface of the cap with silicone lubricant and replace it securely on the test point.

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