ABB Installation Products K655LR-P0380 15/25kV 600 Series Deadbreak Elbow (with Insulated Plug, Cap, Stud, Lug and Cable…

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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 655/675LR and K655/K675LR Deadbreak Elbow Connectors, including cable preparation, lug crimping, and connection to high voltage apparatus. These connectors provide fully shielded, fully submersible deadfront cable connections for 15kV and 25kV class systems.

Estimated time: 1h 30m

1. De-energize Apparatus and Inspect Parts

   DANGER: Ensure all apparatus is de-energized during installation or removal of parts. Do not touch or move energized products. Inspect all connector parts 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 Installation

   Assemble the cable in its final assembled position with enough slack to provide adequate clearance for removing the elbows. 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 a distance of 24” (610mm) or up to the bent back concentric neutral wires.

3. Perform Cable Preparation (Type-Specific)

   Follow the specific cable preparation steps (A, B, or C) that apply to your cable type (e.g., 20MA/21MA grounding device, 600ECS, UNISHIELD, LEAD SHEATH, jacketed, non-jacketed, flat metallic tape, fabric tape, longitudinally corrugated). Refer to any supplementary instructions supplied with specific grounding devices or cable shield adapters (e.g., 10TL) for removal of cable outer jacket, shield connection, and grounding.

4. 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 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 Conductor and Verify Length

   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 exposed conductor length is between 4-1/4” – 4-9/16” (108mm-116mm); if not, redo the assembly.

6. Install and Crimp Compression Lug

   Fully insert the conductor into the compression lug. For aluminum conductors, wire brush the conductor immediately before insertion. 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. Verify the distance from the end of the compression lug to the cable adapter after crimping is between 6-3/8” to 7-1/8” (162mm-181mm); if not, redo the assembly.

7. 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.

8. Prepare and Connect Mating Products

   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. Push the elbow onto the mating part, lining up the hole in the compression lug with the stud on the mating part.

9. Connect Opposite End 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 the instructions supplied with the mating part.

10. 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 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. Do not 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.

12. Perform Voltage Test (Post-Installation)

    Remove the test point cap with a hotstick, peeling off at an angle rather than pulling directly in line with the test point assembly. WARNING: The voltage test point is a capacitance device, not directly connected to the conductor. Use a suitable sensing device made for use with separable connectors manufactured with capacitive test points to determine if the cable is energized. 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. 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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