ABB Installation Products K656CETP-JAC01-DRG 25kv, 600 Amp Series, Deadbreak Combo-T Connector Elbow with Intergral 200 Amp Loadbreak…

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How to Install 655/656/675/676CETP Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe installation and wiring of 655/656/675/676CETP Deadbreak Elbow Connectors, ensuring proper cable preparation, lug crimping, and connection to mating apparatus. Follow all safety warnings for high voltage equipment.

Estimated time: 1h 30m

1. Perform Pre-Installation Checks and Safety Procedures

   DANGER: All apparatus must be de-energized during installation. Inspect all parts for damage, rating, and compatibility. Remove any protective shipping covers and replace with appropriate HV insulated caps or connectors. Check package contents for completeness. Gather all required tools and maintain cleanliness throughout the procedure. This product should only be installed by competent personnel trained in high voltage electrical equipment safety practices.

2. Position Cable and Make Initial Cut

   Position the cable in its final assembled location, ensuring enough slack for elbow removal. If using concentric neutral cable, unwind the concentric neutral wires. Cut the cable 1-3/4 inches (45mm) from the centerline of the mating product.

3. Clean Cable and Remove Outer Jacket

   Clean the outer surface of the cable for a distance of 24 inches (610mm) or up to the bent-back concentric neutral wires. Remove the outer jacket to the dimension shown in the product's detailed diagrams. If using a 20MA/21MA grounding device or 600ECS Jacket Cable Seal, refer to their specific instructions for jacket removal and shield connection.

4. Prepare Cable Shield (Type-Specific)

   Follow the instructions applicable to your cable type: fold back shield wires; remove flat metallic tape shield and secure with vinyl plastic tape; remove fabric tape shield and install tape retainer and marker; remove longitudinally corrugated shield and install tape marker; for UNISHIELD® or lead sheath cable, refer to 10TL cable shield adapter instructions; remove semi-con shield and install tape marker. Do not cut or nick the cable insulation.

5. Bevel Insulation and Install Cable Adapter

   Bevel the end of the cable insulation at a 45-degree angle, approximately 1/4 inch (6mm) back. Thoroughly clean and then lubricate the cable insulation (using supplied lubricant), working towards the semi-con shield. Install the cable adapter, small end first, until it is flush with the edge of the tape marker.

6. Prepare Conductor and Verify Length

   Remove the protruding cable insulation by cutting it even with the end of the cable adapter. Exercise caution to avoid cutting or nicking the cable adapter or the conductor. Verify that the exposed conductor length is between 4-3/8 inches and 4-11/16 inches (111mm-119mm). If not, redo the assembly.

7. Install and Crimp Compression Lug

   For copper conductors, fully insert the conductor into the compression lug. For aluminum conductors, wire brush the conductor immediately before fully inserting it into the lug. Measure the 'Check Dimension' before crimping (must be less than 6-1/2 inches / 165mm). Crimp the lug according to its supplied instructions. Wipe off any excess inhibitor. Verify the distance from the lug end to the cable adapter is 6-1/2 to 7-1/4 inches (165mm-184mm) after crimping.

8. Install Elbow onto Cable Adapter

   Lubricate the cable adapter and the inside of the elbow cable entrance with the supplied lubricant. 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.

9. Prepare Mating Apparatus and Install Stud

   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. Install the stud into the apparatus by hand until it is fully seated. Clean and lubricate both the elbow and the mating part with the supplied lubricant, ensuring surfaces remain clean.

10. Connect Elbow to Mating Part

    Push the elbow onto the mating part. For products dated September 30, 2013, or earlier, use the 600AT assembly tool to engage the hex broach and torque the contact assembly until the torque limiter ratchets (19-25 ft/lbs). For products dated October 1, 2013, or later, use the 600ATM assembly tool and tighten the contact assembly to 50-60 ft/lbs torque, but do not exceed 60 ft/lbs.

11. Ground Cable Shield and Elbow

    Insert one end of a No. 14 AWG Copper wire (or equivalent ampacity) 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. Ensure the cable shield is grounded according to grounding device instructions or an alternate method. It is recommended to waterproof the cable jacket at this point to prevent moisture ingress.

12. Install Tap Plug Interface (Optional)

    If using a tap, clean and lubricate the entire loadbreak interface and the DR(G), ESA, GLR, or LR of the appropriate voltage class with the supplied lubricant. Install the DR(G), ESA, GLR, or LR to the tap plug interface, following the specific instructions provided with those products.

13. Verify Seating and Perform Voltage Test

    Confirm complete assembly by ensuring no portion of the colored interface sleeve is visible when viewed from the side. If applicable, perform a voltage test using the integral capacitance test point. Remove the test point cap with a hotstick (peel off at an angle). WARNING: This is a capacitance device; do not use conventional voltage measuring equipment. Use a suitable sensing device designed for capacitive test points. Treat the elbow as energized until a 'no voltage' indication is confirmed by other means. Clean, lubricate, and replace the cap after testing.

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