ABB Installation Products K656LRTP-J0270-DRG 600 Amp, 25kV, Deadbreak, Stick-Op Connector Kit with Test Point, Cable Insulation…

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How to Install K656/K676LR Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe installation and setup of K656/K676LR Deadbreak Elbow Connectors, including cable preparation, lug crimping, and connection to mating apparatus. These connectors are designed for fully shielded, submersible deadfront cable connections on 15kV and 25kV class systems.

1. Perform Initial Safety Checks and Inspection

   DANGER: All apparatus must be de-energized during installation or removal of parts. Inspect package contents and all components to ensure they are complete, undamaged, and compatible with mating parts. If the product is supplied with protective shipping covers, remove them and replace with appropriate HV insulated caps or connectors before submerging or energizing the circuit. This product should only be installed by competent personnel trained in high voltage electrical equipment safety practices.

2. Position and Clean the Cable

   Position the cable so it is located in its final assembled position, ensuring enough slack for adequate clearance when removing elbows. For concentric neutral cable, unwind the concentric neutral wires. Cut the cable 1-3/4” (45mm) from the centerline of the mating product. Clean the outer surface of the cable for a distance of 24” (610mm) or up to the bent-back concentric neutral wires.

3. Prepare the Cable Jacket and Shield

   Remove the outer jacket to a dimension of 12 3/4” (324mm). Based on your specific cable type (e.g., shield wires, flat metallic tape, fabric tape, longitudinally corrugated, semi-con), follow the corresponding instructions to remove or fold back the shield and install any necessary tape markers or retainers. If using UNISHIELD* CABLE or LEAD SHEATH CABLE, refer to the Installation Instructions supplied with the 10TL cable shield adapter for cable preparation and grounding. Do not cut or nick the cable insulation during this process.

4. Install Cable Adapter and Prepare Conductor

   Bevel the end of the cable insulation at a 45-degree angle, approximately 1/4” (6mm) back. Thoroughly clean, 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. 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 exposed conductor should be 4 3/8”–4 11/16” (111mm–119mm); otherwise, redo the assembly.

5. Crimp the 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 into the compression lug. Measure the “Check Dimension” before crimping; this dimension should be less than 6 1/2” (165mm), otherwise redo the assembly. 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 should be 6 1/2”–7 1/4” (165mm–184mm); otherwise, redo the assembly.

6. Install the Elbow and Prepare Mating Products

   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. DO NOT CONNECT OR DISCONNECT MATING PRODUCTS WHILE ENERGIZED. 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 already equipped with a stud. Clean and lubricate both the elbow and the mating part with the lubricant supplied.

7. Connect the Elbow to the Mating Apparatus

   Push the elbow onto the mating part, carefully lining up the hole in the compression lug with the stud on the mating part. If connecting a mating part for the opposite end of the elbow, clean and lubricate it, then insert it into the elbow. Engage the threads and hand tighten. Torque the mating part according to the instructions supplied with that specific mating part. CAUTION: When constructing 600amp L-Kits, ensure each component is tightened to the specified torque per instructions provided.

8. Install Insulating Plug (Optional) and Ground the Cable Shield

   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 hard until the cap snaps into place. CAUTION: The insulating plug provides a means for detecting system voltage. 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, without damaging 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 any grounding device, or through an alternate method if no device is used. It is also recommended that the jacket of the cable be waterproofed at this point to prevent moisture from entering the cable.

9. Perform Voltage Test (Post-Installation)

   To perform a 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, to determine if the cable is energized. Treat the elbow as energized until a “no voltage” test point indication is confirmed by other means to prevent serious or fatal injury. After voltage detection, clean and lubricate the inside surface of the cap with silicone grease and replace it on the test point.

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