ABB Installation Products K655LRTP-H0270 600 Amp, 25kV, Stick-Op Connector Kit. Aluminum Compression Lug. Cable Insulation…

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How to Install K655/K675LR Deadbreak Elbow Connectors

This guide provides step-by-step instructions for installing K655/K675LR Deadbreak Elbow Connectors, designed for fully shielded, submersible deadfront cable connections to high voltage apparatus and for splicing 600-ampere or 900-ampere systems.

Estimated time: 1h 30m

1. Prepare Cable for Assembly

   DANGER: All apparatus must be de-energized during installation or removal of parts. 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 concentric neutral wires. Cut the cable 1-3/4 inches (45mm) from the center line of the mating product.

2. Clean Cable Outer Surface

   Clean the outer surface of the cable a distance of 24 inches (610mm) or up to the bent back concentric neutral wires.

3. Prepare Cable (Jacket Removal and Shield Preparation)

   Remove the outer jacket (where applicable) and prepare the cable as shown in the diagrams, ensuring correct dimensions for cable insulation, semi-con shield, and tape marker. If using a 20MA or 21MA grounding device, 600ECS Jacket Cable Seal, or 10TL cable shield adapter for UNISHIELD* or LEAD SHEATH cable, refer to the specific installation instructions supplied with those products.

4. Install Cable Adapter

   Bevel the end of the cable insulation at a 45-degree angle, approximately 1/4 inch (6mm) back. Thoroughly clean, 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.

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. Ensure the length of the exposed conductor is between 4-1/4 inches and 4-9/16 inches (108mm-116mm). If not, redo the assembly.

6. Crimp Compression Lug

   For copper conductor, fully insert the conductor into the compression lug. For aluminum conductor, wire brush the conductor and immediately fully insert it into the compression lug. Measure the 'Check Dimension' before crimping; it should be less than 6-3/8 inches. If not, redo the assembly. 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 inches to 7-1/8 inches (162mm-181mm). If not, redo the assembly.

7. Install Elbow

   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. If not, reposition the cable adapter. Remove the tape marker.

8. Prepare Mating Products

   DANGER: DO NOT CONNECT OR DISCONNECT MATING PRODUCTS WHILE ENERGIZED. DO NOT ENERGIZED WHILE DISCONNECTED. Remove protective caps from the elbow and the mating part. If the mating part is not equipped with a stud, hand tighten the threaded stud supplied with the elbow into the mating part. Clean and lubricate both the elbow and the mating part with the supplied lubricant, keeping surfaces clean.

9. Connect Elbow to Mating Part

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

10. 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.

11. 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 and place it on the elbow. Push down hard until the cap snaps into place. Follow voltage test directions after this step.

12. Ground the Cable Shield

    Insert one end of a No. 14 AWG Copper wire (or equivalent ampacity) through the grounding eye and twist to make a small loop, taking care not to damage the eye. Connect the 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. If no grounding device is used, ground the shield through an alternate method. It is also recommended to waterproof the cable jacket at this point to prevent moisture entry.

13. Torque Components (for 600A L-Kits)

    CAUTION: When constructing 600amp L-Kits, ensure each component is tightened to the specified torque per its instructions.

14. Perform Voltage Test

    Remove the test point cap with a hotstick, peeling it off at an angle rather than pulling directly. WARNING: The voltage test point is a capacitance device, 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. To prevent serious or fatal injury, treat the elbow as energized until the 'no voltage' test point indication is confirmed by other means, as contamination, moisture, or incorrect equipment can provide a false 'no voltage' indication. 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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