ABB Installation Products K655LRM2380 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 655/675LR and K655/K675LR Deadbreak Elbow Connectors. It covers cable preparation, lug crimping, final assembly, grounding, and voltage testing for these 15kV and 25kV class system connectors.

Estimated time: 1h 30m

1. Position and Cut Cable

   DANGER: All apparatus must be de-energized during installation or removal. 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 center line of the mating product.

2. 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.

3. Prepare Cable Insulation and Shield

   Follow the specific cable preparation steps (A, B, or C) that apply to your cable type. This involves removing the outer jacket (if applicable) and preparing the cable insulation and semi-con shield according to the provided diagrams and dimensions. If using a grounding device (20MA, 21MA) or jacket cable seal (600ECS), refer to their specific instructions. For UNISHIELD* or LEAD SHEATH cable, use a 10TL cable shield adapter and its instructions.

4. 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 towards 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

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

6. 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; 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 lug and cable adapter. After crimping, the distance from the end of the lug to the cable adapter must be between 6-3/8” to 7-1/8” (162mm-181mm). If dimensions are incorrect, redo the assembly.

7. 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; reposition if necessary. Remove the tape marker.

8. Prepare Mating Part and Stud

   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 one. Clean and lubricate both the elbow and the mating part with the supplied lubricant, ensuring surfaces remain clean. WARNING: DO NOT CONNECT OR DISCONNECT MATING PRODUCTS WHILE ENERGIZED. DO NOT ENERGIZE WHILE DISCONNECTED.

9. Connect Elbow to 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. Install and Torque Opposite Mating Part (if applicable)

    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, tighten each component to the specified torque.

11. Install Insulating Plug and 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 the cap on the elbow and push down hard until it snaps into place. Proceed to voltage test directions.

12. Ground Cable Shield

    Insert one end of a wire (at least No. 14 AWG Copper) 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 supplied with a grounding device, or use an alternate method if no device is present. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

13. Perform Voltage Test - Remove Cap

    The ELASTIMOLD deadbreak elbow connector has an integral capacitance test point. To use it, remove the test point cap with a hotstick. When removing, peel off at an angle rather than pulling directly in line with the test point assembly.

14. Perform Voltage Test - Test for Energization

    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 specific meter used. Test with a suitable sensing device designed for separable connectors with capacitive test points to determine if the cable is energized. Contamination, moisture, dirt, or incorrect equipment can cause a false 'no voltage' indication. Treat the elbow as energized until the 'no voltage' indication is confirmed by other means to prevent serious or fatal injury.

15. Perform Voltage Test - Replace 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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