ABB Installation Products K676LR-J2270 15/25kV, 900 Amp, DeadBreak, Elbow with Test Point (includes Insulated Plug, Cap, Stud…

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

This guide provides detailed instructions for the safe and proper installation of 600-ampere and 900-ampere deadbreak elbow connectors on 15kV and 25kV class systems. DANGER: All apparatus must be de-energized during installation or removal of parts. This product should be installed only by competent personnel trained in good safety practices involving high voltage electrical equipment.

Estimated time: 2h

1. Inspect Components

   Check the package contents to ensure they are complete and undamaged. Inspect all components for damage, proper rating, and compatibility with the cable and/or mating products.

2. Assemble Cable and Cut

   Assemble the cable in its final position, ensuring enough slack to provide adequate clearance for removing 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.

3. Clean Cable Outer Surface

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

4. Prepare Cable

   Prepare the cable by removing the outer jacket (if applicable) and other layers to the specified dimensions: Cable Insulation at 9-3/4” (248mm), Semi-con Shield at 10-3/4” (273mm), and Tape Marker at 12-3/4” (324mm) from the mating product centerline. For specific cable types (e.g., UNISHIELD, Lead Sheath) or if using grounding devices (20MA/21MA) or seals (600ECS), consult their respective installation instructions for detailed 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 towards the semi-con shield. Install the cable adapter, small end first, until it is flush with the edge of the tape marker.

6. Expose 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. Verify the exposed conductor length is 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. 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. Verify the distance from the end of the compression lug to the cable adapter is 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

   Remove any protective shipping covers from the elbow and the mating part, replacing them with appropriate HV insulated caps or connectors if submerging or energizing. Hand tighten the threaded stud (supplied with the elbow) into the mating part if it is not already equipped. Clean and lubricate both the elbow and the mating part with the supplied lubricant, ensuring surfaces remain clean.

10. Connect Elbow to Mating Part

    Push the elbow onto the mating part, carefully 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 this mating part into the elbow. Engage the threads and hand tighten. Torque the mating part according to the instructions supplied with that specific mating part.

12. Install Insulating Plug 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 firmly until the cap snaps into place.

13. Ground the Cable Shield

    Insert one end of a 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; ground according to the instructions supplied with any grounding device, or through an alternate method if no device is used. It is also recommended to waterproof the cable jacket at this point to prevent moisture from entering the cable.

14. Perform Voltage Test

    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 off at an angle rather than pulling directly. Test with a suitable sensing device, made for use with separable connectors manufactured with capacitive test points, to determine if the cable is energized, following the manufacturer’s directions for the meter used. Contamination, moisture, dirt, or using the wrong equipment can provide a false 'no voltage' indication. 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 lubricant and replace it on the test point.

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