K676BCCP

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How to Install K655/K656CCP Deadbreak Elbow Connectors

This guide provides detailed instructions for installing K655/K656CCP Deadbreak Elbow Connectors, ensuring fully shielded and submersible deadfront cable connections for 15kV or 25kV class high voltage systems. It covers cable preparation, connector assembly, and proper grounding procedures.

Estimated time: 2h

1. De-energize and Inspect Components

   DANGER: All apparatus must be de-energized during installation or removal of parts to prevent serious or fatal injury. Inspect all components for damage, proper rating, and compatibility with mating parts. If the product is supplied with protective shipping covers, remove them and replace with appropriate HV insulated caps or connectors before submerging or energizing the circuit.

2. Position and Clean Cable

   Position the cable in its final assembled location, ensuring enough slack for adequate clearance to remove the elbows. For concentric neutral cable, unwind the concentric neutral wires. Cut the cable 1-3/4” (45mm) from the centerline of the mating product. Clean the outer surface of the cable for a distance of 24” (610mm) or up to the bent back concentric neutral wires.

3. Prepare Cable Outer Jacket and Shield

   Remove the cable's outer jacket to a dimension of 12 3/4” (324mm). Follow the specific instructions for your cable shield type: For shield wires, fold them back. For flat metallic tape shield, remove it and secure with vinyl plastic tape to 10 3/4” (273mm). For fabric tape shield, remove it and install a tape retainer and tape marker to 9 3/4” (248mm) and 10 3/4” (273mm) respectively. For longitudinally corrugated shield, remove it and install a tape marker flush to 10 3/4” (273mm). For semi-con shield, remove it and install a tape marker to 9 3/4” (248mm) and 10 3/4” (273mm), ensuring not to cut or nick the cable insulation. Note: If using UNISHIELD* or lead sheath cable, refer to the installation instructions supplied with the 10TL cable shield adapter.

4. Prepare Cable Insulation and 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.

5. Prepare Conductor and Install Compression Lug

   Remove the protruding cable insulation by cutting it even with the end of the cable adapter, taking care not to cut or nick the cable adapter or the conductor. Verify the exposed conductor length is 4 3/8”–4 11/16” (111mm–119mm); if incorrect, redo the assembly. 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” (must be less than 6 1/2” (165mm)) before crimping. Crimp the compression lug following its supplied instructions, locating the first crimp on the end closest to the cable. Wipe all excess inhibitor from the compression lug and cable adapter surface after crimping. Verify the distance from the end of the compression lug to the cable adapter is 6 1/2”–7 1/4” (165mm–184mm); if incorrect, redo the assembly.

6. Install Elbow and Connect to Mating Product

   Lubricate the cable adapter and the inside of the elbow cable entrance. Install the elbow onto the cable adapter until it cannot advance further, ensuring the cable adapter remains flush with the tape marker. Reposition the cable adapter if necessary. Remove the tape marker. DANGER: Do not connect or disconnect mating products while energized. Do not energize while disconnected. Remove protective caps from both the elbow and the mating part. Install the stud in the mating part. Clean and lubricate both the elbow and the mating part with the supplied lubricant. Push the elbow onto the mating part. Using the 600 ATM assembly tool, thread the connector into the mating part until it bottoms. Apply 50 to 60 foot-pounds torque.

7. 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, ensuring not to damage the eye. Connect this wire to ground using a suitable connector. The shield of the cable must be grounded according to the instructions supplied with the grounding device; if no grounding device is used, ground the shield through an alternate method. It is also recommended to waterproof the cable jacket at this point to prevent moisture from entering the cable.

8. Perform Voltage Test (K656CCP Only)

   If applicable (K656CCP only), remove the test point cap with a hotstick, peeling off at an angle rather than pulling directly in line with the test point assembly. 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 meter used. Test with a suitable sensing device, made for use with separable connectors manufactured with capacitive test points, to determine if the cable is energized. WARNING: Contamination, moisture, dirt, etc., around the test point or use of the wrong measuring equipment can provide a false “no voltage” indication on an energized elbow. To prevent serious or fatal injury, treat the elbow as energized until the “no voltage” test point indication is confirmed by other means. 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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