ABB Installation Products K676CHSL-BUS 25kV, 900 Amp, Deadbreak, Compact 4-Way (H) Insulated BUS Bar with Test Point and…

How to Install the K676CHSL-BUS Disconnectable Splice

This guide provides step-by-step instructions for installing the K676CHSL-BUS 28kV disconnectable splice with a sacrificial cap. It covers cable preparation, component assembly, grounding, and final cap installation. DANGER: All apparatus must be de-energized during installation or removal of parts to prevent serious injury or death.

Estimated time: 2h

1. De-energize and Prepare Cable Ends

   DANGER: Ensure all apparatus is de-energized before beginning any work. Cut the cable end square and wipe the outer jacket clean 38 inches from the cut end. Inspect all parts for damage, rating, and compatibility with mating parts.

2. Install Grounding Device and Receptacle Housing

   If an ECS grounding device is being used, slide its tube onto the cable a distance of 38 inches from the cut end. Subsequently, slide the receptacle housing onto the cable a distance of 30 inches from the cut end.

3. Perform Cable Preparation

   Refer to the special cable preparation supplement (Part A for Jacketed Concentric Neutral Cable or Part B for Flat Metallic Tape Shielded Cable with Semi-con Shield) included with these instructions and follow the procedure for your specific cable type. This involves precise jacket removal, insulation shield removal, beveling the insulation, and thoroughly cleaning the insulation to remove all semi-conducting residue.

4. Prepare Conductor and Retaining Ring

   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 conductor. The length of exposed conductor should be 4 3/4 to 5 inches. Assemble aluminum retaining rings over the conductor, snug them firmly against the cable adapter, and hand tighten the socket head screw using the provided hex wrench. Confirm the exposed conductor measures 4 3/8 to 4 3/4 inches.

5. Install and Crimp Connector

   Remove the protective cap from the crimp connector. If using aluminum cable, wire brush the conductor and immediately insert it fully into the crimp connector containing inhibitor. As a final check prior to crimping, position all components on all cables as shown in the instructions, ensuring the bolt holes in the crimp connectors align properly with the bolt holes of the mating part. Crimp the connectors following the instructions packaged with them, rotating each crimp 90 or 180 degrees. After crimping, measure the distance from the end of the connector to the holding collar; if it is over 7 inches, recheck all previous work.

6. Repeat for Additional Cables

   Repeat Steps 4 and 5 for all remaining cables that are to be joined by the splice.

7. Assemble and Torque Bolts

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

8. Lubricate and Position Receptacle Housing

   Apply the supplied lubricant or an 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 its final position, then insert the supplied nylon venting rod.

9. Use Assembly Tool

   Utilize the appropriate assembly tool (e.g., 600YADT-2 or 600RRT-2) as per its specific instruction sheet (IS-1307 or IS-1333) to fully seat the components.

10. Complete Remaining Cables and Final Checks

    Repeat Steps 8 and 9 for any remaining cables. Check all cable adapters to make sure they are located properly and remove all vinyl tape markers.

11. Ground the Assembly

    Complete the installation of any ECS grounding device following its specific instructions. Connect a short length of No. 14 AWG copper wire (or equivalent) to the grounding eyes of the housings, making a small loop and twisting tightly, taking care not to damage the eye. Attach this wire directly to the system's ground; do not use one of the concentric neutral wires for this connection.

12. Install Sacrificial Cap

    Remove the protective shipping cap. Clean the male interface and lubricate both the interface and the inside of the new sacrificial cap with the supplied lubricant. Install the new sacrificial cap by rotating it clockwise 9 to 10 turns until it stops turning; additional torque is not required. Ensure the gap between the cap and the shoulder of the splice is 1/8 inch or less. Attach a 14 AWG wire through the grounding eye and tighten by twisting, then attach it directly to system's ground, keeping the wire snug.

13. Perform Voltage Test (Optional)

    WARNING: The voltage test point is a capacitance device; it is not directly connected to the conductor. Do not use conventional voltage measuring equipment. Remove the test point cap with a hotstick, peeling it off at an angle rather than pulling directly in line. Use a suitable sensing device, made for use with separable connectors manufactured with 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. After voltage detection, clean and lubricate the inside surface of the cap with supplied lubricant and replace it on the test point.

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