ABB Installation Products K656RLR-M0410 600 Amp, 15/25kV, 600 Series Deadbreak, Replacement Elbow with Test Point, Cable…

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How to Install the K655RLR High Voltage Connector

This guide provides detailed instructions for installing the K655RLR connector, designed for fully shielded connections to high voltage apparatus up to 28kV class systems. It covers assembly, cable preparation, and final connection.

Estimated time: 1h 30m

1. Prepare for Installation and Safety Check

   DANGER: Ensure all apparatus is de-energized during installation or removal of parts. Do not touch or move energized products. This product must be installed only by competent personnel trained in high voltage electrical equipment safety. Check the package contents for completeness and damage. Inspect all components for proper fit with the cable and/or mating products. Gather all required tools and maintain cleanliness throughout the procedure.

2. Assemble "I" Adapter into Elbow

   Remove protective caps from the elbow. Clean and lubricate the "I" adapter and the inside of the elbow with the supplied lubricant; do not substitute. Assemble the "I" adapter into the elbow until the spade contact bottoms inside. Ensure the flat side of the "I" contact faces away from the apparatus.

3. Prepare and Connect Elbow to Mating Part

   Remove protective caps from the elbow and the mating part. If the mating part lacks a stud, hand tighten the threaded stud (supplied with the elbow) into it. Clean and lubricate both the elbow and the mating part with the supplied lubricant, keeping surfaces clean. Position the elbow so the flat side of the "I" contact faces away from the apparatus. Push the elbow onto the mating part, aligning the hole in the "I" adapter lug with the stud on the mating part.

4. Connect Mating Part to 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 supplied instructions. If an insulating plug is used, clean and lubricate the inner surface of the voltage detection cap, then place it on the elbow, pushing down hard until it snaps into place.

5. Prepare Cable for Receptacle Housing

   Slide the receptacle housing onto the cable. Holding the cable in place, cut the cable 1 3/4" from the center of the bolt hole in the "I" adapter. Remove the semi-con shield 11 1/8" from the center of the bolt hole in the adapter; if the shield dimension exceeds this, restore it with a semi-con sleeve (not supplied). At 1" from the end of the semi-con shield, wrap two turns of tape as a marker. Bevel the end of the insulation at a 45-degree angle approximately 1/4" back.

6. Clean Cable Insulation and Install Cable Adapter

   Thoroughly clean the insulation to remove all traces of semi-conducting residue by wiping with a rag soaked in an approved safety solvent, always wiping from the end of the cable toward the outer jacket. Apply supplied lubricant sparingly along the cable. Lubricate the inside of the cable adapter. Slide the adapter, small end first, over the cable with a twisting motion until its end is flush with the tape marker.

7. Trim Cable Insulation and Secure Retaining Ring

   Remove the protruding cable insulation by cutting it even with the end of the cable adapter, being careful not to cut or nick the adapter or conductor. Verify the exposed conductor length is between 4 3/16" to 5 1/8"; if not, redo the assembly. Assemble the aluminum retaining ring over the conductor and snug it firmly against the cable adapter. Using the provided hex wrench, tighten the socket head screw until the wrench twists. As a check, measure the exposed conductor; it should be in the range of 4 5/16" to 4 7/8".

8. Prepare and Pre-check Compression Connector

   Remove the protective cap from the compression connector. If using aluminum cable, wire brush the conductor and immediately insert it into the crimp connector (which contains inhibitor), ensuring it's fully inserted into the crimp barrel. As a final check, bolt the crimp connector onto the "I" Adapter and tighten to 25 ft/lbs. Position all components on all cables as shown. Properly train the cable into its final position and mark the alignment points on the retaining ring and the outside surface of the crimp connector.

9. Crimp Connector and Final Bolt Assembly

   Remove the bolted contact from the "I" Adapter. Align the marks on the retaining ring and the crimp connector to confirm proper orientation. Crimp the connectors following their packaged instructions, rotating each crimp 90 or 180 degrees. After crimping, measure the distance from the end of the connector to the holding collar; if over 7 1/8", do not proceed and recheck all previous work. Ensure the flat surface of the "I" Adapter aligns with the flat surface on the crimp connector with no gaps. Assemble the washers and bolt: flat washer against the spade contact, then the Belleville washer (concave side down), then the hex-head bolt. Hand tighten the bolt. Using a torque wrench with a 9/16" socket, tighten the bolt to 50 to 60 ft-lbs. Do not move or reposition any part of the assembly after the bolt is tightened.

10. Lubricate Adapters and Slide Receptacle Housing

    Clean and lubricate the outside of the cable adapter and the "I" adapter with the supplied lubricant. Slide the receptacle housing over the cable adapter and up to the position shown. Insert the nylon venting rod (supplied).

11. Use Assembly Tool and Seat Receptacle

    Attach the appropriate assembly tool (650ATY or 600RRT) as shown in its instructions. For 650ATY, ensure the "U" yoke is over the "I" Adapter and the "C" yoke over the receptacle housing, then slowly raise the handle to slide the housing. For 600RRT, place the tool as shown and turn the hex nut to slide the housing (WARNING: Do not place hand on threaded rod or guide shaft). Remove the vent rod. Remove the assembly tool. Rotate the receptacle approximately 1/8" clockwise then 1/8" counterclockwise by hand to ensure it is seated.

12. Ground Concentric Neutral Cable

    Connect a short length of No. 14 AWG copper wire (or equivalent) to the grounding eyes of the housings, making a small loop and twisting tightly without damage. Gather concentric neutral wires and connect them together with the grounding wires using suitable connectors. The metallic shield of the cable must be grounded using standard utility practices. If the cable is jacketed, waterproof the jacket at this point to prevent moisture entry.

13. Perform Voltage Test (Verification)

    Remove the test point cap with a hotstick, peeling it off at an angle. Using a suitable sensing device, determine if the circuit is energized. DO NOT USE CONVENTIONAL VOLTAGE MEASURING EQUIPMENT. WARNING: The voltage test point is a capacitance device, not directly connected to the conductor. Contamination or incorrect measuring equipment can provide a false "no voltage" indication. Treat the elbow as energized until the "no voltage" 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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