ABB Installation Products K656LR-H0330 15/25kV 600 Amp Series Deadbreak Elbow with Test Point (with Insulated Plug, Cap, Stud…

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How to Install 655/675LR and K655/K675LR Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe and proper installation of 600-ampere and 900-ampere deadbreak elbow connectors on 15kV and 25kV class systems. It covers cable preparation, connector assembly, and initial voltage testing. All apparatus must be de-energized during installation by competent personnel.

Estimated time: 1h 30m

1. De-energize Apparatus and Inspect Parts

   DANGER: All apparatus must be de-energized during installation or removal of parts. Do not touch or move energized products in the work area. Inspect all parts for damage, proper rating, and compatibility with mating parts before proceeding.

2. Check Package Contents and Component Compatibility

   Verify that the package contents are complete and undamaged. Check all components to ensure proper fit with the cable and/or mating products. Read the entire installation instructions before starting.

3. Assemble Cable and Clean Outer Surface

   Assemble the cable in its final position with enough slack to allow 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.

4. Prepare Cable Outer Jacket and Shield

   Remove the outer jacket (if applicable) and prepare the cable according to the specific type (e.g., non-jacketed concentric neutral, jacketed shield wires, flat metallic tape shield, fabric tape shield, longitudinally corrugated shield). Refer to specific instructions for 20MA/21MA grounding devices, 600ECS Jacket Cable Seal, or 10TL cable shield adapters if being used.

5. Bevel, Clean, Lubricate, and Install 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, always working toward the semi-con shield. Install the cable adapter, small end first, until it is flush with the edge of 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 must be between 4-1/4 inches and 4-9/16 inches (108mm-116mm). If not, redo the assembly.

7. Insert Conductor into Compression Lug and Crimp

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

8. Lubricate and Install Elbow onto Cable Adapter

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

9. Prepare Mating Product for Connection

   WARNING: Do not connect or disconnect mating products while energized. Do not energize while disconnected. Remove protective caps from the elbow and the mating part. Hand tighten the threaded stud supplied with the elbow into the mating part if the mating part is not equipped with a stud. Clean and lubricate both the elbow and the mating part with the supplied lubricant, keeping surfaces clean.

10. Push Elbow onto Mating Part and Align

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

11. Connect Opposite Mating Part

    Clean and lubricate the mating part 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 the instructions supplied with that specific mating part.

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 hard until it snaps into place. Follow voltage test directions below.

13. Ground the Cable Shield

    Insert one end of a wire (at least equivalent to No. 14 AWG Copper) through the grounding eye and twist to make 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 either through a grounding device (following its instructions) or an alternate method.

14. Waterproof Cable Jacket

    It is recommended to waterproof the jacket of the cable at this point to prevent moisture from entering the cable.

15. Verify Component Torque

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

16. Perform Voltage Test

    Remove the test point cap with a hotstick, peeling it off at an angle. WARNING: The voltage test point is a capacitance device, not directly connected to the conductor. Do not use conventional voltage measuring equipment. Use a suitable sensing device, made for separable connectors with capacitive test points, to determine if the cable is energized. Treat the elbow as energized until the 'no voltage' indication is confirmed by other means to prevent serious or fatal injury.

17. Reinstall Test Point Cap

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

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