ABB Installation Products K656CY-L0320 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 the safe installation and wiring of K656/K676 series deadbreak receptacles for 600 ampere, 15kV and 25kV solid dielectric cables. These instructions cover the installation of one leg of the connector.

Estimated time: 1h 30m

1. Ensure Safety and Inspect Components

   DANGER: All apparatus must be de-energized during installation or removal. This product should be installed only by competent personnel trained in good safety practices involving high voltage electrical equipment. Inspect all parts for damage, proper rating, and compatibility with mating parts. Remove any protective shipping covers and replace with appropriate HV insulated caps or connectors before submerging or energizing the circuit. Check contents of package to ensure they are complete and undamaged.

2. Clean and Cut 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, with respect to the interface.

3. Install ECS Grounding Device Tube (if applicable)

   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 onto Cable

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

5. Prepare Jacketed Concentric Neutral Cable

   Refer to the special cable preparation supplement for your specific cable type (e.g., Jacketed Concentric Neutral Cable or Flat Metallic Tape Shielded Cable). For Jacketed Concentric Neutral Cable: 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 and out of the way. Measure 10-1/4 inches (26 cm) from the cable end and remove the semi-con from the insulation with a straight, smooth, 'squared' cut, taking care not to cut or nick the insulation. At 1 inch (2.54 cm) from the end of the semi-con shield, wrap two turns of tape to serve 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 supplied 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 Insulation and Verify Conductor Length

   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. The length of the exposed conductor should be 4-3/4 inches to 5 inches (12.07 cm - 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 - 12.07 cm). If not, redo the assembly.

8. Prepare and Insert 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 the distance is over 7 inches (17.78 cm), do not proceed; recheck all previous work.

9. Confirm Component Alignment

   Prior to crimping the connector, confirm that all components (receptacle housing, cable adapter, crimp connector) are positioned correctly. Ensure the bolt holes in the crimp connectors are positioned properly to align with the bolt holes of the mating part.

10. 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 the distance is over 7 inches (17.78 cm), do not proceed; redo all previous work.

11. 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. 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.

12. Torque Tighten Bolts

    Using a torque wrench with a 15/16 inch socket, tighten all bolts to 50 to 60 ft. lbs. (67.8 - 81.3 Nm).

13. Lubricate Cable Adapter and Receptacle Mating Surface

    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.

14. 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).

15. Fully Seat Receptacle Housing with Assembly Tool

    Attach the 650ATY assembly tool as shown in the product documentation, ensuring the 'U' shaped yoke is over the splice section and the 'C' shaped yoke is over the receptacle housing. With the assembly tool in place, slowly raise the handle to slide the receptacle housing over the splice section. Remove the venting rod. WARNING: DO NOT place hand on threaded rod or guide shaft with the assembly tool in place if using the 600RRT tool.

16. Perform Final Checks and Grounding

    Check all cable adapters to make sure they are located properly and remove all vinyl tape markers. Complete the installation of any ECS grounding device according to its specific instructions. Connect a short length of No. 14 AWG copper wire (or equivalent) to the grounding eyes of the housings, making a small loop and twisting tightly, taking care not to damage the eye. Connect this wire to ground.

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