ABB Installation Products K675LR-M5380 900 Amp, 15/25kV, 600 Series Elbow with Insulated Plug, Cap, Stud, Lug and Cable…

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How to Install 655/675LR and K655/K675LR Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe and proper installation of 655/675LR and K655/K675LR deadbreak elbow connectors on 15kV and 25kV class systems, including cable preparation, assembly, and initial voltage testing.

Estimated time: 1h 30m

1. De-energize Apparatus and Inspect Parts

   DANGER: All apparatus must be de-energized during installation or removal of parts. Inspect all parts for damage, correct rating, and compatibility with mating parts. Remove any protective shipping covers and replace with appropriate HV insulated caps or connectors before submerging or energizing the circuit.

2. Prepare Cable for Assembly

   Assemble the cable in its final position with enough slack to provide adequate clearance for removing the elbows. For concentric neutral cable, unwind the neutral wires. Cut the cable 1-3/4” (45mm) from the centerline of the mating product.

3. Clean Cable Surface

   Clean the outer surface of the cable for a distance of 24” (610mm) or up to the bent-back concentric neutral wires.

4. Perform Cable Preparation

   Follow the specific instructions for your cable type (e.g., non-jacketed, jacketed shield wires, flat metallic tape shield, fabric tape shield, longitudinally corrugated shield) to remove the outer jacket (where applicable) and prepare the cable as shown in the diagrams. If using a 20MA or 21MA grounding device or 600ECS Jacket Cable Seal, refer to their supplied instructions. If using UNISHIELD* or LEAD SHEATH cable, refer to the 10TL cable shield adapter instructions for cable preparation.

5. Install Cable Adapter

   Bevel the end of the cable insulation at a 45-degree angle, approximately 1/4” (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.

6. Prepare 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 exposed conductor should be between 4-1/4” – 4-9/16” (108mm-116mm). Otherwise, redo the assembly.

7. Crimp Compression Lug

   For copper conductors, fully insert the conductor into the compression lug. For aluminum conductors, wire brush the conductor and immediately fully insert it into the compression lug. Measure the “Check Dimension” before crimping (this dimension should be less than 6-3/8”). 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 between 6-3/8” to 7-1/8” (162mm-181mm). Otherwise, redo the assembly.

8. Install Elbow

   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.

9. Prepare Mating Products

   DO NOT CONNECT OR DISCONNECT MATING PRODUCTS WHILE ENERGIZED. DO NOT ENERGIZE WHILE DISCONNECTED. Remove protective caps from 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 equipped with a stud. Clean and lubricate both the elbow and the mating part with the lubricant supplied, keeping surfaces clean.

10. Connect Elbow to Mating Part

    Push the elbow onto the mating part, lining up the hole in the compression lug with the stud on the mating part.

11. Connect Opposite Mating Part (if applicable)

    Clean and lubricate the mating part for the opposite end of the elbow. Insert the mating part into the elbow. Engage the threads and hand tighten. Torque the mating part according to the instructions supplied with the mating part.

12. Install Insulating Plug and Cap (if applicable)

    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. Follow voltage test directions below.

13. Ground the Cable Shield

    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. Do not damage the eye. Connect this wire to ground using a suitable connector. The shield of the cable must be grounded. Ground according to the instructions supplied with the grounding device. If no grounding device is used, the shield must be grounded through an alternate method.

14. Waterproof Cable Jacket

    It is recommended that the jacket of the cable be waterproofed at this point to prevent moisture from entering the cable.

15. Perform Voltage Test (Pre-energization)

    Remove the test point cap with a hotstick, peeling it off at an angle rather than pulling directly in line. WARNING: The voltage test point is a capacitance device, not directly connected to the conductor. Do not use conventional voltage measuring equipment. Use a suitable sensing device made for capacitive test points to determine if the cable is energized. Treat the elbow as energized until the “no voltage” test point indication is confirmed by other means to prevent serious or fatal injury, as contamination or incorrect equipment can provide a false reading. After testing, clean and lubricate the inside surface of the cap with silicone lubricant and replace it on the test point.

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