ABB Installation Products K655LR-M0330 600 Amp, 15/25kV, 600 Series Deadbreak, Elbow with Insulated Plug, Cap, Stud, Lug and…

Frequently Asked Questions

How to Install 655/675LR and K655/K675LR Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe and proper installation of 600-ampere and 900-ampere deadbreak elbow connectors on 15kV and 25kV class systems. It covers cable preparation, connector assembly, and post-installation voltage testing.

Estimated time: 1h 30m

1. De-energize Apparatus and Inspect Parts

   DANGER: De-energize all apparatus in the work area before beginning installation or removal of any part. Inspect all components for damage, correct rating, and compatibility with mating parts. Remove any protective shipping covers and replace with appropriate HV insulated caps or connectors before submerging or energizing the circuit.

2. Prepare Cable for Connection

   Assemble the cable in its final position with enough slack to allow 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. Clean the outer surface of the cable for a distance of 24” (610mm) or up to the bent-back concentric neutral wires. Remove the outer jacket (where applicable) and prepare the cable as shown in the documentation for your specific cable type (e.g., non-jacketed, jacketed shield wires, flat metallic tape shield, fabric tape shield, or longitudinally corrugated shield).

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

4. Prepare Conductor and Install Compression Lug

   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 exposed conductor must be between 4-1/4” to 4-9/16” (108mm-116mm). 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 (this dimension should be less than 6-3/8”). Crimp the compression lug following the crimping instructions supplied with the lug. Wipe all excess inhibitor from the compression 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” to 7-1/8” (162mm-181mm).

5. Install Elbow Connector

   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. Make sure the cable adapter is still flush with the tape marker; if not, reposition the cable adapter. Remove the tape marker.

6. Connect to Mating Product

   DANGER: 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 threaded stud supplied with the elbow into the mating part, if the mating part is not equipped with a stud. Clean and lubricate both the elbow and the mating part with the lubricant supplied, keeping surfaces clean. Push the elbow onto the mating part, lining up the hole in the compression lug with the stud on the mating part.

7. Connect Opposite End (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 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.

8. 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, ensuring not to damage the eye. Connect this wire to ground using a suitable connector. The shield of the cable must be grounded; ground according to the instructions supplied with the grounding device, or through an alternate method if no grounding device is used. It is also recommended that the jacket of the cable be waterproofed at this point to prevent moisture from entering the cable.

9. Perform Voltage Test (Post-Installation)

   Remove the test point cap with a hotstick, peeling it off at an angle rather than pulling directly in line with the test point assembly. WARNING: The voltage test point is a capacitance device and is NOT directly connected to the conductor. Do not use conventional voltage measuring equipment. Follow the manufacturer’s directions for the meter used. Test with a suitable sensing device, made for use with separable connectors manufactured with capacitive test points, to determine if the cable is energized. Treat the elbow as energized until the “no voltage” test point indication is confirmed by other means to prevent serious or fatal injury. After voltage detection, clean and lubricate the inside surface of the cap with silicone lubricant and replace it on the test point.

Frequently Asked Questions about ABB - Installation Products