ABB Installation Products K656YDSR-M0380 15-25kV 600 Series Deadbreak Direct Test Straight Receptacle Elbow with Test Point…

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How to Install Deadbreak Receptacles with Direct Access Port

This guide provides detailed instructions for installing K656DCY, K656DCH, and K656DI deadbreak receptacles, designed to splice and tap solid dielectric cables for high-current applications. It covers cable preparation, assembly, and initial setup.

Estimated time: 2h

1. Prepare for Installation and Safety Checks

   DANGER: Ensure all apparatus is de-energized during installation or removal of parts. Do not touch or move energized products. Inspect all parts for damage, rating, and compatibility with mating parts. Check package contents for completeness. Wipe the outer jacket of the cable clean for a distance of 38 inches. If using an ECS sealing device, slide the tube onto the cable 38 inches. Slide the receptacle housing onto the cable 30 inches.

2. Prepare the Cable (Select Type)

   Follow the specific procedure for your cable type. For Jacketed Concentric Neutral Cable: From the cable end, remove 13-3/4 inches of jacket and 10-1/4 inches of semi-con, taking care not to damage neutral wires or insulation. Bend neutral wires back. Wrap two turns of tape 1 inch from the semi-con end. Bevel the insulation end at a 45-degree angle for 1/4 inch. Thoroughly clean the insulation with an approved safety solvent, wiping from the cable end toward the outer jacket. Apply lubricant sparingly along the cable and inside the cable adapter. Slide the adapter, small end first, over the cable with a twisting motion until flush with the tape marker. For Flat Metallic Tape Shielded Cable with Semi-con Shield: From the cable end, remove 13-3/4 inches of outer jacket. Remove 11-1/4 inches of tape shield, wrap a conductive copper strip around the edge, and wrap two turns of tape over the end of the tape shield and copper strip, with the tape edge 11-1/4 inches from the outer jacket end. Remove 10-1/4 inches of semi-con shield. Bevel the insulation end at a 45-degree angle for 1/4 inch. Thoroughly clean the insulation with an approved safety solvent, wiping from the cable end toward the outer jacket. Apply lubricant sparingly along the cable and inside the cable adapter. Slide the adapter, small end first, over the cable with a twisting motion until flush with the tape marker.

3. Assemble Retaining Ring and Crimp Connector

   Remove any protruding cable insulation, cutting it even with the end of the cable adapter. Do not cut or nick the adapter or conductor. The exposed conductor should measure 4-3/4 to 5 inches. Assemble the aluminum retaining ring over the conductor and snug 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 to 4-3/4 inches. 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 containing inhibitor. Measure the distance from the end of the connector to the retaining ring; if over 7 inches, redo previous work. Repeat cable preparation and this step for all remaining cables to be joined. Prior to crimping, confirm components are positioned as shown in the instructions, ensuring bolt holes in the crimp connectors align with the mating part.

4. Crimp Connectors and Secure Splice

   Crimp each connector following the instructions packaged with the connectors. Rotate each crimp 90 or 180 degrees. After crimping, measure the distance from the end of the connector to the holding collar; if over 7 inches, redo previous work. Assemble the washers and bolt in the following order: flat washer against spade contact, Belleville washer (concave side down), hex-head bolt. Hand tighten. The splice and cables are now in their final positions; do not attempt to move or reposition any part of the assembly after bolts are tightened. Using a torque wrench with a 15/16 inch socket, tighten each bolt to 50 to 60 ft. lbs.

5. Install Receptacle Housing

   Apply supplied 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. Insert the nylon venting rod (supplied). Use either the 650ATY or 600RRT assembly tool to slide the receptacle housing over the splice section. WARNING: Do not place hands on the threaded rod or guide shaft with the assembly tool in place. Remove the venting rod once the housing is in place. Repeat the lubrication and housing installation steps for any remaining cables.

6. Final Checks and Grounding

   Check all cable adapters to ensure they are located properly and remove all vinyl tape markers. Complete the installation of any ECS grounding device according to its instructions. Connect a short length of No. 14 AWG copper wire (or equivalent) to the grounding eyes of the housings. Make a small loop and twist tightly, taking care not to damage the eye, and connect to ground.

7. Perform Direct Voltage Test (Optional)

   To perform a direct test, a specific meter and test cap are required. DANGER: Not following these instructions or inserting objects other than the test cap can cause serious or fatal injury. The elbow access port provides direct access to the cable conductor. Contact with the uncovered port or insertion of objects other than the insulated cap or voltage 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 following instructions packaged with the voltage test cap. Refer to the operating instructions included with the meter and test cap for voltage measurement.

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