ABB Installation Products K656CH-M0380 600 Amp, 15/25 kV, Separable H Joint package 4-Way with Test Point, Cable Insulation…

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How to Install K656CH Deadbreak Receptacles

This guide provides step-by-step instructions for the safe and proper installation of K656CH Deadbreak Receptacles, designed for splicing and tapping solid dielectric type cables rated for 600 ampere at 15kV and 25kV. It covers cable preparation, connector assembly, and grounding procedures for one leg of the connector.

Estimated time: 1h 45m

1. Prepare for Installation and Perform Safety Checks

   DANGER: Ensure all apparatus is de-energized before beginning installation. Do not touch or move energized products. Inspect all package contents to ensure they are complete and undamaged. Verify all components fit properly with the cable and/or mating products. Check threads by threading a probe into the compression lug; if resistance is encountered, check for damage and replace the component. This product must be installed only by competent personnel trained in high voltage electrical equipment safety practices.

2. Prepare Cable and Slide Initial Components

   Wipe the outer jacket of the cable clean for a distance of 38 inches (96.5 cm) from the end. Cut the cable end squarely to ensure maximum available length for crimp growth. If using an ECS grounding device, slide the tube onto the cable a distance of 38 inches (96.5 cm). Slide the receptacle housing onto the cable a distance of 30 inches (76.2 cm).

3. Perform Cable Specific Preparation

   Refer to the special cable preparation supplement for your cable type. For Jacketed Concentric Neutral Cable: Measure 13-3/4 inches (34.9 cm) from the cable end and remove the jacket, taking care not to damage neutral wires. Bend neutral wires back. Measure 10-1/4 inches (26 cm) from the end and remove the semi-con shield with a straight, smooth cut. At 1 inch (2.5 cm) from the semi-con shield end, wrap two turns of tape as a marker. Bevel the insulation end at a 45-degree angle, approximately 1/4 inch (0.6 cm) back. Thoroughly clean the insulation with an approved safety solvent, wiping from the cable end toward the outer jacket. Lubricate the cable sparingly and the inside of the cable adapter. Slide the adapter, small end first, over the cable with a twisting motion until it is flush with the tape marker. For Flat Metallic Tape Shielded Cable with Semi-con Shield: Measure 13-3/4 inches (34.9 cm) from the cable end and remove the outer jacket with a straight, smooth cut, taking care not to damage the tape shield. Measure 11-1/4 inches (28.6 cm) and remove the tape shield to that point. Wrap a conductive copper strip around the edge to secure the tape shield, then wrap two turns of tape over the end of the tape shield and copper strip, with the tape edge 11-1/4 inches (28.6 cm) from the outer jacket end. Measure 10-1/4 inches (26 cm) and remove the semi-con shield with a straight, smooth cut. Bevel the insulation end at a 45-degree angle, approximately 1/4 inch (0.6 cm) back. Thoroughly clean the insulation with an approved safety solvent, wiping from the cable end toward the outer jacket. Lubricate the cable sparingly and the inside of the cable adapter. Slide the adapter, small end first, over the cable with a twisting motion until it is flush with the tape marker.

4. Prepare Conductor and Assemble Retaining Ring

   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 exposed conductor length should be 4-3/4 to 5 inches (12.1 to 12.7 cm); if not, redo the assembly. Assemble the aluminum retaining ring over the conductor and snug it firmly against the cable adapter. Using the provided hex wrench, tighten the socket head screw hand tight. Confirm the exposed conductor measures 4-3/8 to 4-3/4 inches (11.1 to 12.1 cm); if not, redo the assembly.

5. Install Crimp Connector

   Remove the protective cap from the crimp connector. If using aluminum cable, wire brush the conductor immediately before fully inserting it into the crimp connector, which contains inhibitor. Measure the distance from the end of the connector to the holding collar. If this distance is over 7 inches (17.8 cm), do not proceed; redo all previous work. Repeat steps 4 and 5 for any remaining cables to be joined.

6. Crimp Connectors

   Before crimping, confirm that all components are positioned correctly and that the bolt holes in the crimp connectors are aligned with the bolt holes of the mating part. Crimp the connectors following the instructions packaged with the connectors, rotating each crimp 90 or 180 degrees. After crimping, measure the distance from the end of the connector to the holding collar. If this distance is over 7 inches (17.8 cm), do not proceed; redo all previous work.

7. Assemble and Torque Bolts

   Assemble the washers and bolt in the following order: flat washer against the spade contact, Belleville washer (concave side down), then the hex-head bolt. Hand tighten the bolt. 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. Using a torque wrench with a 15/16 inch socket, tighten all bolts to 50 to 60 ft. lbs. (67.8 to 81.3 Nm).

8. Lubricate and Position Receptacle Housing

   Apply the supplied lubricant or an ELASTIMOLD approved lubricant generously to the outside of the cable adapter, the area of the splice section as shown in the diagram, 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 diagram). Insert the supplied nylon venting rod.

9. Complete Receptacle Housing Assembly

   Attach the appropriate assembly tool (650ATY or 600RRT). If using the 650ATY tool, ensure the 'U' shaped yoke is over the splice section and the 'C' shaped yoke is over the receptacle housing. Slowly raise the handle to slide the receptacle housing over the splice section. If using the 600RRT tool, slide the receptacle housing over the interface by turning the hex nut on either end of the tool. WARNING: Do not place hands on the threaded rod or guide shaft with the assembly tool in place. Remove the venting rod once the housing is fully assembled. Repeat steps 8 and 9 for any remaining cables.

10. Perform Final Checks and Grounding

    Check all cable adapters to ensure they are located properly and remove all vinyl tape markers. If using an ECS grounding device, complete its installation according to its specific instructions. 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, and connect it to ground.

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