ABB Installation Products K656LR-M5380-S 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 or 900-ampere deadbreak elbow connectors on 15kV and 25kV class systems, including cable preparation, connector assembly, and grounding. Ensure all apparatus is de-energized before beginning installation.

Estimated time: 2h

1. Prepare Cable Slack and Cut

   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. DANGER: All apparatus must be de-energized during installation.

2. Clean 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.

3. Prepare Cable Insulation and Shield

   Remove the outer jacket (if applicable) and prepare the cable end according to the specific cable type (e.g., non-jacketed, jacketed shield, flat metallic tape, fabric tape, or longitudinally corrugated shield) as detailed in the documentation. Ensure proper dimensions for cable insulation, semi-con shield, and tape marker placement. If using a 20MA/21MA grounding device or 600ECS Jacket Cable Seal, refer to their specific instructions. For UNISHIELD* or LEAD SHEATH cable, use a 10TL cable shield adapter and its instructions.

4. 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 towards the semi-con shield. Install the cable adapter, small end first, until it is flush with the edge of the tape marker.

5. Expose Conductor

   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 not, redo the assembly.

6. 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. Measure the 'Check Dimension' before crimping; this dimension must be less than 6-3/8 inches. Crimp the compression lug following the supplied crimping instructions. Wipe off all excess inhibitor from the 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 to 7-1/8 inches (162mm-181mm). If not, redo the assembly.

7. 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. Verify the cable adapter is still flush with the tape marker; reposition if necessary. Remove the tape marker.

8. Prepare Mating Part

   Remove protective caps from both the elbow and the mating part. If the mating part 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, keeping surfaces clean. WARNING: Do not connect or disconnect mating products while energized. Do not energize while disconnected.

9. Connect Elbow to Mating Part

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

10. Connect Second Mating Part (if applicable)

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

11. Install Insulating Plug or Voltage Detection Cap (if used)

    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. Push down firmly until the cap snaps into place. Proceed to voltage test directions.

12. Ground Cable Shield

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

13. Perform Voltage Test

    Use the integral capacitance test point to determine if the circuit is energized. Remove the test point cap with a hotstick, peeling off at an angle rather than pulling directly. 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 designed for separable connectors with capacitive test points, following its manufacturer's directions. Contamination, moisture, dirt, or incorrect equipment can provide a false 'no voltage' indication. To prevent serious or fatal injury, 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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