ABB Installation Products K656LR-J0230-S 15/25kV 600 Amp Series Deadbreak Elbow with Test Point (with Insulated Plug, Cap, Stud…

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How to Install K655/K675LR and K656LR-J0230-S Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe installation and wiring of K655/K675LR and K656LR-J0230-S Deadbreak Elbow Connectors, including cable preparation, lug crimping, and grounding procedures for 15kV and 25kV class systems.

Estimated time: 1h 30m

1. De-energize Apparatus and Inspect Parts

   DANGER: Ensure all apparatus is de-energized before installation or removal of parts. Do not touch or move energized products. Inspect all package contents and components for completeness, damage, proper rating, and compatibility with cable and mating products. Remove any protective shipping covers and replace with appropriate HV insulated caps or connectors before energizing.

2. Prepare Cable for Assembly

   Assemble the cable in its final position, ensuring enough slack for elbow removal. For concentric neutral cable, unwind the neutral wires. Cut the cable 1-3/4” (45mm) from the center line of the mating product.

3. Clean Cable Outer Surface

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

4. Prepare Cable Jacket and Shield

   Follow specific instructions for your cable type (e.g., 20MA/21MA grounding device, 10TL cable shield adapter, or jacketed/non-jacketed cable). Remove the outer jacket (if applicable) and prepare the cable according to the dimensions provided in the documentation diagrams for cable insulation, semi-con shield, and tape marker placement.

5. Bevel, Clean, and Lubricate Cable Insulation

   Bevel the end of the cable insulation at a 45-degree angle, approximately 1/4” (6mm) back. Thoroughly clean the cable insulation, then lubricate it, always working toward the semi-con shield.

6. Install Cable Adapter

   Install the cable adapter, small end first, onto the cable insulation until it is flush with the edge of the tape marker.

7. Prepare 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” and 4-9/16” (108mm-116mm). If not, redo the assembly.

8. Insert and Crimp Compression Lug

   For copper conductors, fully insert the conductor into the compression lug. For aluminum conductors, wire brush the conductor immediately before fully inserting it. Measure the 'Check Dimension' before crimping (must be less than 6-3/8”). Crimp the lug following its supplied instructions. Wipe all excess inhibitor. After crimping, the distance from the lug end to the cable adapter must be 6-3/8” to 7-1/8” (162mm-181mm). Redo if not.

9. 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.

10. Prepare Mating Products

    DANGER: 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 it is not already equipped. Clean and lubricate both the elbow and the mating part with the supplied lubricant, keeping surfaces clean.

11. Connect Elbow to Mating Part

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

12. Connect Opposite End of Elbow

    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 its specific instructions.

13. Install Insulating Plug and Cap (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. Prepare to follow voltage test directions.

14. Ground the Cable Shield

    Insert one end of a grounding wire (with ampacity at least equivalent to No. 14 AWG Copper) through the grounding eye and twist to form a small loop without damaging the eye. Connect this wire to ground using a suitable connector. The cable shield must be grounded; follow instructions for your grounding device or use an alternate method. Waterproof the cable jacket to prevent moisture ingress.

15. Torque L-Kit Components (If Applicable)

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

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 capacitive test points to determine if the cable is energized. Contamination, moisture, dirt, or incorrect equipment can give a false 'no voltage' indication. Treat the elbow as energized until the 'no voltage' indication is confirmed by other means. After testing, clean and lubricate the inside surface of the cap with silicone lubricant and replace it on the test point.

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