ABB Installation Products K656LR-J0240 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 detailed instructions for the safe and proper installation of 600-ampere and 900-ampere deadbreak elbow connectors on 15kV and 25kV class systems. Ensure all apparatus are de-energized before beginning installation.

Estimated time: 1h 30m

1. De-energize Apparatus and Inspect Components

   De-energize all apparatus in the work area before beginning installation or removal of any parts. Failure to follow this instruction will result in serious or fatal injury. Check the contents of the connector kit to ensure all parts are complete and undamaged. Verify all components for proper fit with the cable and/or mating products. Gather all required tools and maintain cleanliness throughout the procedure.

2. Prepare Cable for Connection

   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 inches (45mm) from the centerline of the mating product. Clean the outer surface of the cable a distance of 24 inches (610mm) or up to the bent-back concentric neutral wires. Follow the specific cable preparation instructions (A, B, or C) that apply to your cable type (e.g., UNISHIELD, Lead Sheath, Jacketed, Non-Jacketed) for outer jacket removal, shield connection, and grounding. Prepare the cable insulation, semi-con shield, and shield wires/tape to the specified dimensions (e.g., 9-3/4 inches, 10-3/4 inches, 12-3/4 inches from the cut end).

3. Install Cable Adapter and Prepare Conductor

   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 towards the semi-con shield. Install the cable adapter, small end first, until it is flush with the edge of the tape marker. 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 exposed conductor length must be between 4-1/4 inches and 4-9/16 inches (108mm-116mm). If the length is outside this range, redo the assembly.

4. Crimp 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 compression lug. Measure the 'Check Dimension' before crimping; this dimension should be less than 6-3/8 inches. Crimp the compression lug following the crimping instructions supplied with the lug. Wipe all excess inhibitor from the compression lug and cable adapter surface after crimping. The distance from the end of the compression lug to the cable adapter after crimping must be between 6-3/8 inches and 7-1/8 inches (162mm-181mm). If the dimension is outside this range, redo the assembly.

5. Install Elbow Connector

   Lubricate the cable adapter and the inside of the elbow cable entrance. Install the elbow onto the cable adapter until the elbow cannot advance further. Make sure the cable adapter is still flush with the tape marker; if not, reposition the cable adapter. Remove the tape marker.

6. Connect Elbow to Mating Apparatus

   WARNING: Do not connect or disconnect mating products while energized. Do not energize while disconnected. Remove protective caps from both 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. Push the elbow onto the mating part, lining up the hole in the compression lug with the stud on the mating part. If connecting to the opposite end of the elbow, clean and lubricate that mating part, insert it into the elbow, engage the threads, hand-tighten, and torque according to its specific instructions. If an insulating plug is used as a mating part, clean and lubricate the inner surface of the voltage detection cap and place it on the elbow, pushing down hard until it snaps into place.

7. Ground the Cable Shield

   Insert one end of a piece of wire with ampacity 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 shield of the cable must be grounded according to the instructions supplied with the grounding device. If no grounding device is used, the shield must be grounded through an alternate method. It is also recommended that the jacket of the cable be waterproofed at this point to prevent moisture from entering the cable. For 600-amp L-Kits, ensure each component is tightened to the specified torque per instructions provided.

8. Perform Voltage Test

   Remove the test point cap with a hotstick, peeling it off at an angle rather than pulling directly in line with the test point assembly. WARNING: The voltage test point is a capacitance device and is not directly connected to the conductor. Do not use conventional voltage measuring equipment. Test with a suitable sensing device, made for use with separable connectors manufactured with capacitive test points, following the manufacturer’s directions. Contamination, moisture, dirt, or incorrect equipment can provide a false 'no voltage' indication on an energized elbow. To prevent serious or fatal injury, treat the elbow as energized until the 'no voltage' test point indication is confirmed by other means. After voltage detection, clean and lubricate the inside surface of the cap with silicone lubricant and replace it on the test point.

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