ABB Installation Products K656YDSR-M0330 15-25kV 600 Series Deadbreak Direct Test Straight Receptacle Elbow with Test Point…

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How to Install K656 Series Deadbreak Receptacles

This guide provides step-by-step instructions for the safe installation and assembly of K656DCY, K656DCH, and K656DI Deadbreak Receptacles with Direct Access Ports on solid dielectric type cables.

Estimated time: 2h

1. Prioritize Safety

   DANGER: All apparatus must be de-energized during installation or removal of parts. Do not touch or move energized products. This product should be installed only by competent personnel trained in good safety practices involving high voltage electrical equipment. Failure to follow instructions will result in damage and serious injury.

2. Inspect Components

   Check contents of the package to ensure they are complete and undamaged. Inspect all components to ensure proper fit with the cable and/or mating products. Read the entire installation instructions before starting and have all required tools at hand, maintaining cleanliness throughout the procedure.

3. Prepare Cable End

   Wipe the outer jacket clean for a distance of 38 inches. Cut the cable end square to ensure maximum available length for crimp growth. If an ECS sealing device is being used, slide the tube onto the cable for a distance of 38 inches. Slide the receptacle housing onto the cable for a distance of 30 inches.

4. Perform Cable Specific Preparation

   Refer to the special cable preparation supplement included with these instructions and follow the procedure for your specific cable type (Jacketed Concentric Neutral Cable or Flat Metallic Tape Shielded Cable with Semi-con Shield). This involves precise jacket/shield removal, bending neutral wires, marking, beveling insulation, and thoroughly cleaning the cable surface.

5. Install Cable Adapter

   Remove any protruding cable insulation by cutting it even with the end of the cable adapter, taking care not to cut or nick the adapter or conductor. The exposed conductor should measure 4 3/4" - 5". 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 hand tight. Confirm the exposed conductor measures 4 3/8" - 4 3/4".

6. Prepare and Insert Conductor

   Remove the protective cap from the crimp connector. If using aluminum cable, wire brush the conductor and immediately fully insert it into the crimp connector which contains inhibitor. Measure the distance from the end of the connector to the retaining ring. If the distance is over 7" (17.8cm), do not proceed and redo all previous work. Repeat steps 4-6 for all remaining cables to be joined.

7. Align and Crimp Connectors

   Prior to crimping, confirm components are positioned as shown in the instructions and that the bolt holes in the crimp connectors are positioned properly to align with the bolt holes of the mating part. Crimp each connector following the instructions packaged with the connectors, rotating each crimp 90 or 180 degrees. After crimping, measure the distance from the end of the connector to the holding collar. If the distance is over 7", do not proceed and redo all previous work.

8. Assemble Washers and Bolts

   Assemble the washers and bolt in the following order: flat washer against the spade contact, then the Belleville washer (concave side down), and finally the hex-head bolt. Hand tighten the bolt. The splice and cables are now in their final positions.

9. Torque Tighten Bolts

   Using a torque wrench with a 15/16" socket, tighten each bolt to 50 to 60 ft. lbs. Do not attempt to move or reposition any part of the assembly after the bolts are tightened.

10. Lubricate and Position Housing

    Apply supplied lubricant or ELASTIMOLD approved lubricant generously to the outside of the cable adapter, the area of the splice section, and the inside mating surface of the receptacle housing. Slide the receptacle housing over the cable adapter and up to the edge of the interface (position shown in instructions). Insert the nylon venting rod (supplied).

11. Complete Housing Assembly

    Attach the appropriate assembly tool (650ATY or 600RRT) as shown in the instructions. With the assembly tool in place, slowly raise the handle or turn the hex nut to slide the receptacle housing over the splice section. Remove the venting rod. WARNING: Do not place hand on threaded rod or guide shaft with the assembly tool in place. Repeat steps 10-11 for any remaining cables.

12. Final Checks and Grounding

    Check all cable adapters to make sure they are located properly and remove all vinyl tape markers. Complete the installation of any ECS grounding device according to the instructions included with that device. Connect a short length of No. 14 AWG copper wire (or equivalent) to the grounding eyes of the housings and to ground.

13. Perform Direct Test (Optional)

    To perform a direct test, a specific meter and test cap are required. The operating instructions for voltage measurement are included with the meter and test cap. DANGER: Not following these instructions or insertion of objects other than the test cap can cause serious or fatal injury. Removal of the insulated cap and installation of the voltage test cap must be done with a hotstick tool.

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