ABB Installation Products K676LR-M2290 900 Amp, Elbow Connector, with Test Point, with Insulated Plug, Cap, Stud, Lug and Cable…

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How to Install 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, designed for fully shielded, submersible cable connections to high voltage apparatus.

Estimated time: 1h

1. Prepare for Installation and Safety Checks

   DANGER: All apparatus must be de-energized during installation or removal of parts. Do not touch or move energized products. Verify package contents are complete and undamaged. Inspect all components for proper fit with the cable and/or mating products. Gather all required tools and maintain a clean work environment. Ensure installation is performed only by competent personnel trained in good safety practices involving high voltage electrical equipment.

2. Prepare Cable for Connection

   Assemble the cable in its final position, ensuring enough slack for elbow removal. If using concentric neutral cable, unwind the neutral wires. Cut the cable 1-3/4 inches (45mm) from the centerline of the mating product. Clean the outer surface of the cable for a distance of 24 inches (610mm) or up to the bent-back concentric neutral wires. Remove the outer jacket (where applicable) and prepare the cable insulation and semi-con shield according to the specific cable type and diagrams provided in the full instructions (e.g., 9-3/4", 10-3/4", 12-3/4" dimensions).

3. Install Cable Adapter

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

4. Prepare Conductor and Crimp Lug

   Remove the protruding cable insulation by cutting it even with the end of the cable adapter, being careful not to cut or nick the cable adapter or conductor. The exposed conductor length must be between 4-1/4 inches and 4-9/16 inches (108mm-116mm); otherwise, redo 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' before crimping; it must be less than 6-3/8 inches. Crimp the compression lug according to 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 after crimping is between 6-3/8 inches to 7-1/8 inches (162mm-181mm); otherwise, redo assembly.

5. Install Elbow onto Cable Adapter

   Lubricate the cable adapter and the inside of the elbow cable entrance. Install the elbow onto the cable adapter until it cannot advance further. Ensure the cable adapter remains flush with the tape marker; reposition if necessary. Remove the tape marker.

6. Connect Elbow to Mating Product

   WARNING: Do not connect or disconnect mating products while energized. Do not energize while disconnected. Remove protective caps from the elbow and the mating part. If the mating part is not equipped with a stud, hand tighten the threaded stud (supplied with the elbow) into the mating part. Clean and lubricate both the elbow and the mating part with the supplied lubricant, ensuring surfaces remain clean. Push the elbow onto the mating part, lining up the hole in the compression lug with the stud on the mating part.

7. Connect Opposite End of Elbow (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 the mating part. CAUTION: When constructing 600amp L-Kits, ensure each component is tightened to the specified torque per instructions provided.

8. Install Insulating Plug (if used)

   If an insulating plug is used as a mating part, clean and lubricate the inner surface of the voltage detection cap. Place the cap on the elbow and push down hard until it snaps into place.

9. 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, taking care 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 the grounding device, or via an alternate method if no grounding device is used. It is also recommended that the jacket of the cable be waterproofed at this point to prevent moisture from entering the cable.

10. Perform Voltage Test (Optional but Recommended)

    Remove the test point cap using a hotstick, peeling it 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 that is 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. 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 has been made, clean and lubricate the inside surface of the cap with silicone lubricant and replace it on the test point.

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