ABB Installation Products K656CY-H0240 15-25kV 600 Series Deadbreak Separable Wye Joint Package (3-Way) with Test Point, Cable…

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How to Install K656/K676 Series Deadbreak Receptacles

This guide provides detailed instructions for installing K656 and K676 series deadbreak receptacles, including cable preparation, crimping, and final assembly for splicing and tapping solid dielectric cables. These instructions cover the installation of one leg; repeat for additional cables as needed.

Estimated time: 1h 30m

1. De-energize Apparatus and Inspect Components

   DANGER: All apparatus must be de-energized during installation or removal of parts. Do not touch or move energized products. Failure to follow instructions will result in serious injury. Inspect all parts for damage, proper rating, and compatibility with mating parts. Ensure all required tools and supplies are at hand and maintain cleanliness.

2. Clean and Square Cable End

   Wipe the outer jacket 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.

3. Slide ECS Grounding Device Tube (Optional)

   If an ECS grounding device is being used, slide the tube onto the cable a distance of 38 inches (96.5 cm) from the end.

4. Slide Receptacle Housing

   Slide the receptacle housing onto the cable a distance of 30 inches (76.2 cm) from the end.

5. Prepare Jacketed Concentric Neutral Cable (Part A)

   Measure 13-3/4 inches (34.9 cm) from the cable end and remove the cable jacket with a straight, smooth cut, taking care not to damage neutral wires. Bend neutral wires back. Measure 10-1/4 inches (26 cm) from the cable end and remove the semi-con shield with a straight, smooth, squared cut, avoiding nicks to the insulation. At 1 inch (2.54 cm) from the end of the semi-con shield, wrap two turns of tape as a marker. Bevel the end of the insulation at a 45-degree angle, approximately 1/4 inch (0.64 cm) back. Thoroughly clean the insulation with an approved safety solvent, wiping from the cable end toward the outer jacket. Apply lubricant sparingly along the cable and inside the cable adapter. Slide the adapter, small end first, over the cable with a twisting motion until the end of the adapter is flush with the tape marker.

6. Remove Protruding Cable Insulation

   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 be 4 3/4 inches to 5 inches (12.07 cm to 12.7 cm). If not, redo the assembly.

7. Assemble Aluminum Retaining Ring

   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 inches to 4 3/4 inches (11.11 cm to 12.07 cm). If not, redo the assembly.

8. Prepare Crimp Connector

   Remove the protective cap from the crimp connector. If using aluminum cable, wire brush the conductor and immediately insert it into the crimp connector, which contains inhibitor. Ensure the conductor is fully inserted into the crimp barrel. Measure the distance from the end of the connector to the holding collar; if it is over 7 inches (17.78 cm), do not proceed and recheck all previous work.

9. Repeat for Additional Cables

   Repeat Steps 5 through 8 for all remaining cables to be joined in the splice.

10. Confirm Component Alignment Before Crimping

    Prior to crimping, confirm that all components are positioned correctly and that the bolt holes in the crimp connectors are properly aligned with the bolt holes of the mating part.

11. Crimp Connectors

    Crimp the connectors following the instructions packaged with the connectors. Rotate each crimp 90 or 180 degrees. After crimping, measure the distance from the end of the connector to the holding collar; if it is over 7 inches (17.78 cm), do not proceed and redo all previous work.

12. Assemble Washers and Bolt

    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. Clean and lubricate the bolt and washer assembly area.

13. Torque Tighten 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.

14. Apply Lubricant for Assembly

    Apply the supplied lubricant or 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.

15. Slide Receptacle Housing and Insert Venting Rod

    Slide the receptacle housing over the cable adapter and up to the edge of the interface. Insert the nylon venting rod (supplied).

16. Use Assembly Tool to Complete Housing Slide

    Attach the appropriate assembly tool (650ATY or 600RRT). If using 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 to slide the housing over the splice section. If using the 600RRT, slide the housing over the interface by turning the hex nut on either side of the tool. WARNING: DO NOT place hand on threaded rod or guide shaft with the assembly tool in place. Remove the venting rod once the housing is fully seated.

17. Repeat Housing Assembly for Remaining Cables

    Repeat Steps 15 and 16 for all remaining cables to complete the housing assembly for the entire splice.

18. Verify Cable Adapters and Remove Markers

    Check all cable adapters to ensure they are located properly and remove all vinyl tape markers.

19. Complete Grounding

    If an ECS grounding device is used, 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 to ground.

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