ABB Installation Products K656CY-L0360 25kv, 600 Amps, Separable Wye Joint Splice, With Test Point, No Sealing Kit, Deadbreak…

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How to Install K656CY Deadbreak Receptacles

This guide provides step-by-step instructions for the safe and proper installation of K656CY series deadbreak receptacles, including detailed cable preparation, crimping, and final assembly for splicing and tapping solid dielectric cables.

Estimated time: 2h

1. Ensure Safety and Inspect Components

   DANGER: De-energize all apparatus before beginning installation. Do not touch or move energized products. This installation must be performed by competent personnel trained in high voltage electrical equipment and in accordance with all safety practices and electrical standards. Inspect all supplied parts for damage, correct rating, and compatibility with mating components before proceeding.

2. Prepare the Cable Jacket and Slide Initial Components

   Wipe the outer cable 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. If using an ECS grounding device, slide the ECS tube onto the cable 38 inches (96.5 cm). Then, slide the receptacle housing onto the cable a distance of 30 inches (76.2 cm).

3. Perform Cable Preparation (Type-Specific)

   Refer to the specific cable preparation supplement for your cable type. For Jacketed Concentric Neutral Cable: Remove 13-3/4 inches (34.9 cm) of jacket, bend neutral wires back, and remove 10-1/4 inches (26 cm) of semi-con shield. Mark 1 inch (2.5 cm) from the semi-con end with tape. Bevel the insulation end at 45 degrees for approximately 1/4 inch (0.6 cm). Thoroughly clean the insulation with an approved safety solvent, wiping from the cable end towards the outer jacket. Lubricate the cable 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: Remove 13-3/4 inches (34.9 cm) of outer jacket. Remove 11-1/4 inches (28.6 cm) of tape shield, wrap a conductive copper strip around the edge, and secure with two turns of tape marker. Remove 10-1/4 inches (26 cm) of semi-con shield. Bevel the insulation end at 45 degrees for approximately 1/4 inch (0.6 cm). Thoroughly clean the insulation with an approved safety solvent, wiping from the cable end towards the outer jacket. Lubricate the cable 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 Secure Retaining Ring

   Remove the protruding cable insulation by cutting it even with the end of the cable adapter, ensuring not to cut or nick the adapter or conductor. The exposed conductor should measure 4 3/4 to 5 inches (12.1 to 12.7 cm). 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 now measures 4 3/8 to 4 3/4 inches (11.1 to 12.1 cm). If measurements are incorrect, 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 insert it fully into the crimp connector, which contains inhibitor. Measure the distance from the end of the connector to the holding collar; it must be between 6 3/4 and 7 inches (17.1 to 17.8 cm). Confirm that the bolt holes in the crimp connectors are positioned to align properly with the bolt holes of the mating part. Crimp the connectors according to the instructions packaged with them, rotating each crimp 90 or 180 degrees. After crimping, re-measure the distance from the end of the connector to the holding collar; it must still be between 6 3/4 and 7 inches (17.1 to 17.8 cm). Repeat steps 4-5 for all remaining cables to be joined.

6. Assemble Washers and Bolt, Then Torque

   Assemble the washers and hex-head bolt in the following order: flat washer against the spade contact, then the Belleville washer (concave side down), followed by the hex-head bolt. Hand tighten the bolt. Clean and lubricate the bolt and washer assembly. Using a torque wrench with a 15/16 inch socket, tighten all bolts to 50 to 60 ft. lbs. 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 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. Insert the nylon venting rod (supplied).

8. 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, then 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 side of the tool. WARNING: DO NOT place your hand on the threaded rod or guide shaft with the assembly tool in place. Once the housing is fully seated, remove the venting rod. Repeat steps 7-8 for any remaining cables.

9. Perform Final Checks and Grounding

   Check all cable adapters to ensure they are properly located and remove any 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, forming a small loop and twisting tightly, taking care not to damage the eye. Connect this wire to ground.

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