ABB Installation Products K655LR-N0410 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 and proper installation of K655/K675LR Deadbreak Elbow Connectors, including cable preparation, component assembly, and connection to mating apparatus.

Estimated time: 1h 30m

1. Prepare for Installation and Safety Check

   DANGER: Ensure all apparatus is de-energized before beginning installation. Inspect all parts for damage, verify ratings, and confirm compatibility with mating parts. Check package contents for completeness. Read all instructions thoroughly and gather all required tools, maintaining cleanliness throughout the procedure.

2. Prepare the Cable

   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. 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 (if applicable) and prepare the cable insulation and semi-con shield to the dimensions specified in the product documentation (e.g., 9-3/4”, 10-3/4”, 12-3/4” for insulation, semi-con shield, and tape marker respectively).

3. Install the 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 toward 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. DANGER: Do not cut or nick the cable adapter or the conductor. Verify the exposed conductor length is between 4-1/4” and 4-9/16” (108mm-116mm); if not, redo the assembly. 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 must be less than 6-3/8”). Crimp the compression lug according to the instructions supplied with the lug. Wipe all excess inhibitor from the compression lug and cable adapter surface after crimping. Verify the distance from the end of the compression lug to the cable adapter is between 6-3/8” to 7-1/8” (162mm-181mm) after crimping; if not, redo the assembly.

5. 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 is still flush with the tape marker; reposition if necessary. Remove the tape marker.

6. Connect to Mating Apparatus (First End)

   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.

7. Connect Mating Apparatus (Second End) and Torque

   Push the elbow onto the mating part, carefully lining up the hole in the compression lug with the stud on the mating part. 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. CAUTION: When constructing 600amp L-Kits, ensure each component is tightened to the specified torque per instructions.

8. Install Insulating Plug (If Applicable)

   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 hard until it snaps securely into place.

9. Ground the Cable Shield

   Insert one end of a grounding wire (with ampacity at least equivalent to No. 14 AWG Copper) through the grounding eye and twist to make a small loop. DANGER: Do not damage the grounding eye. Connect the wire to ground using a suitable connector. Ensure the shield of the cable is grounded, either according to the instructions supplied with a grounding device or through an alternate method. It is also recommended to waterproof the cable jacket at this point to prevent moisture from entering the cable.

10. Perform Voltage Test

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

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