ABB Installation Products K656LR-G5230-S-TL 15/25kV 600 Amp Series Deadbreak Elbow with Test Point (with Insulated Plug, Cap, Stud…

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How to Install K656LR-G5230-S-TL Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe and proper installation of K656LR-G5230-S-TL deadbreak elbow connectors. It covers cable preparation, connector assembly, and initial voltage testing for 15kV and 25kV class systems.

Estimated time: 1h 30m

1. Perform Initial Safety Checks and Part Inspection

   Ensure all apparatus are de-energized before starting installation. Inspect all parts for damage, verify ratings, and confirm compatibility with mating parts. Check the package contents for completeness and ensure all required tools are at hand. Remove any protective shipping covers and replace them with appropriate HV insulated caps or connectors before energizing the circuit.

2. Prepare the Cable for Assembly

   Assemble the cable in its final position, leaving enough slack to allow for elbow removal. If using concentric neutral cable, unwind the neutral wires. Cut the cable 1-3/4 inches (45mm) from the centerline of the mating product.

3. Clean the Cable Outer Surface

   Clean the outer surface of the cable for a distance of 24 inches (610mm) or up to the bent-back concentric neutral wires.

4. Prepare the Cable Insulation and Shield

   Remove the outer jacket (if applicable) and prepare the cable according to its type (e.g., non-jacketed concentric neutral, jacketed shield wires, flat metallic tape shield, fabric tape shield, or longitudinally corrugated shield). Refer to specific instructions for 20MA/21MA grounding devices or 10TL cable shield adapters if used.

5. 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.

6. Expose the Conductor

   Remove the protruding cable insulation by cutting it even with the end of the cable adapter. Exercise caution to avoid cutting or nicking the cable adapter or the conductor. The exposed conductor length must be between 4-1/4 inches and 4-9/16 inches (108mm-116mm); otherwise, redo the assembly.

7. Crimp the Compression Lug

   For copper conductors, fully insert the conductor into the compression lug. For aluminum conductors, wire brush the conductor and immediately fully insert it into the lug. Measure the 'Check Dimension' before crimping (must be less than 6-3/8 inches). Crimp the compression lug according to its supplied instructions. Wipe off any excess inhibitor. The distance from the end of the lug to the cable adapter after crimping should be 6-3/8 to 7-1/8 inches (162mm-181mm); otherwise, redo the assembly.

8. Install the Elbow onto the Cable Adapter

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

9. Prepare Mating Products

   WARNING: Do not connect or disconnect mating products while energized, and do not energize while disconnected. Remove protective caps from both the elbow and the mating part. If the mating part lacks a stud, hand tighten the threaded stud supplied with the elbow into it. Clean and lubricate both the elbow and the mating part with the provided lubricant, ensuring surfaces remain clean.

10. Connect the Elbow to the Mating Part

    Push the elbow onto the mating part, carefully aligning the hole in the compression lug with the stud on the mating part.

11. Connect the Opposite Mating Part

    Clean and lubricate the mating part intended for the opposite end of the elbow. Insert this mating part into the elbow, engage the threads, and hand tighten. Torque the mating part according to its specific instructions.

12. Install Insulating Plug (If Applicable)

    If an insulating plug is used as a mating part, clean and lubricate the inner surface of the voltage detection cap. Place the cap on the elbow and push down firmly until it snaps into place.

13. Ground the Cable Shield

    Insert one end of a No. 14 AWG Copper equivalent wire through the grounding eye and twist it to form a small loop, taking care not to damage the eye. Connect this wire to ground using a suitable connector. The cable shield must be grounded; follow instructions for any grounding device used, or employ an alternate method if no device is present. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

14. Ensure Proper Torque for L-Kits (If Applicable)

    CAUTION: When constructing 600-amp L-Kits, ensure each component is tightened to the specified torque as per the provided instructions.

15. Remove the Test Point Cap

    Remove the test point cap using a hotstick. When removing, peel it off at an angle rather than pulling directly in line with the test point assembly.

16. Perform Voltage Test

    WARNING: The voltage test point is a capacitance device and is not directly connected to the conductor. Do not use conventional voltage measuring equipment. Use a suitable sensing device designed for capacitive test points to determine if the cable is energized, following the meter manufacturer's directions. Treat the elbow as energized until a 'no voltage' indication is confirmed by other means, as contamination or incorrect equipment can provide false readings, leading to serious or fatal injury.

17. Replace the Test Point Cap

    After voltage detection is complete, clean and lubricate the inside surface of the cap with silicone lubricant and replace it securely on the test point.

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