ABB Installation Products K656CH-DP0592441 600 Amp, 15/25KV, Separable H Joint package, 4-Way with Test Point, 2 X ( Cable…

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How to Install K656 Deadbreak Receptacles

This guide provides step-by-step instructions for the safe and proper installation of K656 series deadbreak receptacles, designed for splicing and tapping solid dielectric cables. It covers cable preparation, connector assembly, and final grounding procedures for one leg of the connector.

Estimated time: 2h

1. Ensure Safety and Inspect Components

   Ensure all apparatus is de-energized during installation or removal of parts to prevent serious injury. Do not touch or move energized products in the work area. Inspect all components of the K656 deadbreak receptacle kit for damage, proper rating, and compatibility with mating parts and the cable. Verify that all threads are clear by threading a probe into the compression lug. This product should be installed only by competent personnel trained in good safety practices involving high voltage electrical equipment.

2. Prepare the Cable End

   Wipe the outer cable jacket clean for a distance of 38 inches from the end, then cut the cable end squarely to ensure maximum available length for crimp growth. Based on your cable type, follow the specific preparation instructions: for Jacketed Concentric Neutral Cable, remove 13-3/4 inches of jacket and 10-1/4 inches of semi-con shield, then bevel the insulation at a 45-degree angle approximately 1/4 inch back. For Flat Metallic Tape Shielded Cable, remove 13-3/4 inches of outer jacket, 11-1/4 inches of tape shield (securing with conductive copper strip and tape), and 10-1/4 inches of semi-con shield, then bevel the insulation at a 45-degree angle approximately 1/4 inch back. Thoroughly clean the insulation with an approved safety solvent, wiping from the cable end towards the outer jacket to remove all traces of semi-conducting residue.

3. Install Receptacle Housing and Cable Adapter

   If an ECS grounding device is being used, slide the ECS tube onto the cable a distance of 38 inches from the end. Slide the receptacle housing onto the cable a distance of 30 inches from the end. Apply the supplied lubricant sparingly along the prepared cable and generously inside the cable adapter. Slide the cable adapter, small end first, over the cable with a twisting motion until its end is flush with the tape marker (if used) or the prepared semi-con shield edge.

4. Prepare Conductor and Secure Retaining Ring

   Carefully remove any 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 length of exposed conductor should measure 4 3/4 to 5 inches. Assemble the aluminum retaining ring over the conductor, snugging it firmly against the cable adapter. Using the provided hex wrench, tighten the socket head screw hand tight. Confirm the exposed conductor now measures 4 3/8 to 4 3/4 inches; otherwise, redo the assembly.

5. Install and Crimp the Connector

   Remove the protective cap from the crimp connector. If using aluminum cable, wire brush the conductor and immediately fully insert it into the crimp connector, which contains inhibitor. Measure the distance from the end of the connector to the holding collar; if it is over 7 inches, do not proceed and redo all previous work. Crimp the connectors following the instructions packaged with the connectors, rotating each crimp 90 or 180 degrees. After crimping, re-measure the distance from the end of the connector to the holding collar, ensuring it remains between 6 3/4 and 7 inches.

6. Assemble and Torque Bolts

   Prior to crimping, confirm components are positioned and bolt holes in the crimp connectors align with the bolt holes of the mating part. Assemble the washers and bolt in the following order: flat washer against the spade contact, Belleville washer with the concave side down, then the hex-head bolt. Hand tighten all bolts. Using a torque wrench with a 15/16 inch socket, tighten all bolts to 50 to 60 ft. lbs. The splice and cables are now in their final positions; do not attempt to move or reposition any part of the assembly after the bolts are tightened.

7. Lubricate and Position Receptacle Housing

   Apply the supplied lubricant or ELASTIMOLD approved lubricant generously to the outside of the cable adapter, the area of the splice section, and the inside mating surface of the receptacle housing. Slide the receptacle housing over the cable adapter and up to the edge of the interface (as shown in the documentation). Insert the nylon venting rod (supplied) into the housing.

8. Complete Final Assembly with Tool

   Attach the appropriate assembly tool (either the 650ATY or 600RRT) as shown in the instructions. For the 650ATY, ensure the 'U' shaped yoke is over the splice section and the 'C' shaped yoke is over the receptacle housing, then slowly raise the handle. For the 600RRT, slide the housing by turning the hex nut. Slowly operate the tool to slide the receptacle housing completely over the splice section. Once fully seated, remove the nylon venting rod. WARNING: DO NOT place hand on the threaded rod or guide shaft with the 600RRT assembly tool in place.

9. Perform Grounding

   After all cable adapters are properly located and any vinyl tape markers are removed, complete the installation of any ECS grounding device according to the instructions included with that device. Connect a short length of No. 14 AWG copper wire (or equivalent) to the grounding eyes of the housings. Make a small loop and twist tightly, taking care not to damage the eye. Connect this wire to a suitable ground point in accordance with individual user, local, and national work rules and electrical standards.

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