ABB Installation Products K656LR-G0240-S 15/25kV 600 Amp Series Deadbreak Elbow with Test Point (with Insulated Plug, Cap, Stud…

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How to Install K656LR-G0240-S Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe and proper installation of K656LR-G0240-S Deadbreak Elbow Connectors, including cable preparation, lug crimping, and connection to high-voltage apparatus.

Estimated time: 2h

1. Prepare for Installation and Ensure Safety

   Before beginning, ensure all apparatus are de-energized. Inspect all components for damage, proper rating, and compatibility with mating parts. Gather all required tools and supplies, and maintain a clean work area. Read the entire installation instructions thoroughly. DANGER: All apparatus must be de-energized during installation or removal. Failure to follow these instructions will result in serious or fatal injury. This product should be installed only by competent personnel trained in good safety practices involving high voltage electrical equipment.

2. Prepare the Cable

   Assemble the cable in its final position, ensuring sufficient slack for elbow removal. For concentric neutral cable, unwind the neutral wires. Cut the cable 1-3/4 inches (45mm) from the centerline of the mating product. Clean the outer surface of the cable for a distance of 24 inches (610mm) or up to the bent-back concentric neutral wires. Remove the outer jacket (if applicable) and prepare the cable insulation and semi-con shield to the specified dimensions (9-3/4, 10-3/4, 12-3/4 inches from the cut end, as shown in the diagrams).

3. Install the Cable Adapter

   Bevel the end of the cable insulation at a 45-degree angle, approximately 1/4 inch (6mm) back. Thoroughly clean and then lubricate the cable insulation, working towards the semi-con shield. Install the cable adapter, small end first, until it is flush with the edge of the tape marker.

4. Prepare Conductor and Crimp Compression Lug

   Remove any protruding cable insulation by cutting it even with the end of the cable adapter, taking care not to cut or nick the cable adapter or the conductor. The exposed conductor length must be between 4-1/4 inches and 4-9/16 inches (108mm-116mm); if not, redo the assembly. For aluminum conductors, wire brush the conductor immediately before insertion. Fully insert the conductor into the compression lug. Measure the 'Check Dimension' before crimping to ensure it is less than 6-3/8 inches. Crimp the compression lug according to the instructions supplied with the lug. Wipe all excess inhibitor from the lug and cable adapter surface. Verify the distance from the end of the compression lug to the cable adapter is between 6-3/8 inches to 7-1/8 inches (162mm-181mm) after crimping; if not, redo the assembly.

5. Install the Elbow Connector

   Lubricate the cable adapter and the inside of the elbow cable entrance. Install the elbow onto the cable adapter, pushing until it cannot advance further. Confirm the cable adapter remains flush with the tape marker; reposition if necessary. Remove the tape marker.

6. Connect to Mating Apparatus

   Remove any protective caps from both the elbow and the mating apparatus. If the mating apparatus is not equipped with a stud, hand tighten the threaded stud supplied with the elbow into the mating part. Clean and lubricate both the elbow and the mating part with the supplied lubricant, ensuring all surfaces remain clean. Push the elbow onto the mating part, carefully aligning the hole in the compression lug with the stud on the mating part. DANGER: Do not connect or disconnect mating products while energized. Do not energize while disconnected.

7. Connect Opposite Mating Part (if applicable)

   If connecting an opposite mating part, clean and lubricate its mating surface. Insert the mating part into the elbow, engage the threads, and hand tighten. Torque the mating part according to the specific instructions provided with that component.

8. Ground the Cable Shield

   Insert one end of a No. 14 AWG Copper wire (or equivalent ampacity) through the grounding eye and twist to form a small loop, being careful not to damage the eye. Connect this wire to ground using a suitable connector. Ensure the cable shield is properly grounded, either through a dedicated grounding device (following its instructions) or an alternate approved method. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

9. Perform Voltage Test and Secure Cap

   If an insulating plug is used as a mating part, clean and lubricate the inner surface of the voltage detection cap and place it firmly on the elbow until it snaps into place. To test for voltage, remove the test point cap with a hotstick, peeling it off at an angle. Use a suitable sensing device, designed for capacitive test points, to determine if the cable is energized, following the meter manufacturer's directions. After voltage detection, clean and lubricate the inside surface of the cap with silicone lubricant and replace it securely on the test point. WARNING: The voltage test point is a capacitance device and is not directly connected to the conductor. Do not use conventional voltage measuring equipment. Contamination, moisture, dirt, or incorrect equipment can provide a false 'no voltage' indication. Treat the elbow as energized until the 'no voltage' indication is confirmed by other means to prevent serious or fatal injury.

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