ABB Installation Products K656SR-L0290 600 Amp, 15/25kV, 600 Series Straight Receptacle with cable adapter, lug and retaining…

Frequently Asked Questions

How to Install K656SR and M656SR Straight Receptacles

This guide provides step-by-step instructions for the safe and proper installation of K656SR and M656SR straight receptacles, ensuring an in-line cable connection to standard ANSI-386 600 amp 15kV, 25kV, or 35kV bushings. Always de-energize all apparatus before beginning installation.

Estimated time: 2h

1. Prepare Apparatus Bushing

   DANGER: All apparatus must be de-energized during installation or removal of parts. If a stud is present in the apparatus bushing, remove it and re-tap the hole using a 5/8-11 tap. Clean and lubricate the apparatus bushing and bushing converter interface. Apply 3-4 drops of Loctite to the threads of the brass bolt. Assemble the bushing converter onto the apparatus bushing, then attach the contact adapter with the bolt hole facing out, using the 5/8 inch brass bolt. Torque the brass bolt to 60 ft-lbs.

2. Prepare Cable End

   Train the cable end and straighten it into its final position. Cut the cable squarely to ensure maximum available length for crimp growth.

3. Manage Concentric Neutral Wires

   If applicable, unwrap the concentric neutral wires a distance of 30 inches (76cm). DO NOT CUT these wires. Bend and fold them back out of the way.

4. Clean Cable Jacket and Position Receptacle Housing

   Wipe the outer jacket of the cable clean for a distance of 38 inches (96.5cm) or up to the concentric neutral wires. Slide the receptacle housing onto the cable a distance of 30 inches (76cm).

5. Prepare Cable Insulation and Semi-con Shield

   Remove the semi-con shield and install a tape marker to the dimensions shown in the documentation (10-1/4 inches or 26.04cm from the end, and 11-1/4 inches or 28.58cm from the end). Be careful not to cut or nick the cable insulation.

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

7. 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 length of the exposed conductor should be 4 3/4 inches to 5 inches (12.06cm-12.7cm). If not, redo the assembly.

8. Install Holding Collar

   Position the holding collar over the conductor and flush against the cable adapter. Using the supplied hex wrench, tighten the setscrew. The exposed conductor length from the holding collar should be 4 3/8 inches to 4 3/4 inches (11.11cm-12.06cm).

9. Prepare and Insert Crimp Connector

   Remove the protective cap from the crimp connector. If using aluminum cable wire, brush the conductor and immediately insert it into the crimp connector, which contains inhibitor. Ensure the conductor is fully inserted into the crimp barrel. Measure the distance from the end of the connector to the holding collar. If this distance is over 7 inches (17.8cm), do not proceed; redo all previous work. The expected distance is 6 3/4 inches to 7 inches (17.14cm-17.8cm).

10. Confirm Component Orientation

    Confirm that all components (Receptacle Housing, Cable Adapter, Crimp Connector, Contact Adapter) are oriented in the correct order. Crucially, confirm that the bolt hole in the crimp connector is aligned with the bolt hole in the contact adapter.

11. Crimp Connectors

    Crimp the connectors following the instructions packaged with the connectors. Rotate each crimp 90 degrees. After crimping, measure the distance from the end of the connector to the holding collar. If the distance is over 7 inches (17.8cm), do not proceed; redo all previous work. The expected distance is 6 3/4 inches to 7 inches (17.14cm-17.8cm).

12. Assemble Washers and Bolt

    Assemble the washers and bolt in the following order: Flat washer against the spade contact, Belleville washer (concave side down), then the hex-head bolt. Hand tighten. The splice and cables are now in their final positions. Using a torque wrench with a 15/16 socket, tighten to 50-60 ft-lbs. Do not attempt to move or reposition any part of the assembly after the bolts are tightened.

13. Lubricate Cable and Bushing Adapters

    Apply the supplied lubricant or ELASTIMOLD approved lubricant generously to the outside of the cable adapter and the area of the bushing adapter as shown in the diagrams. DO NOT SUBSTITUTE other lubricants, as they may be harmful to the product or its mating product.

14. Seat Receptacle Housing and Ground

    Slide the receptacle housing over the cable adapter and up to the edge of the interface. Insert the supplied nylon venting rod. Slide the receptacle housing onto the bushing converter until it is fully seated. Remove the venting rod. Connect a short piece of No. 14 AWG copper wire (or equivalent) to the grounding eye of the receptacle housing, forming a small loop and twisting tightly without damaging the eye. Gather the concentric neutral wires and, using a suitable connector, connect them to the grounding wire.

15. Install Hose Clamp (35kV Only)

    FOR 35kV ONLY: Position the hose clamp between the locator bumps on the receptacle housing. Tighten the clamp until an audible click is heard.

16. Perform Voltage Test (Post-Installation)

    WARNING: The voltage test point is a capacitance device and is not directly connected to the conductor. Do not use conventional voltage measuring equipment. Follow the manufacturer’s directions for the specific meter used. Remove the test point cap with a hotstick, peeling it off at an angle. Test with a suitable sensing device, made for use with separable connectors with capacitive test points, to determine if the cable is energized. Contamination, moisture, dirt, or incorrect equipment can cause 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 testing, clean and lubricate the inside surface of the cap with silicone lubricant and replace it on the test point.

Frequently Asked Questions about ABB - Installation Products