ABB Installation Products K676LR-M2380-S 900 Amp, 15/25kV, 600 Series Elbow with Test Point, with Insulated Plug, Cap, Stud, Lug…

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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 installation, cable preparation, and connection of 600-ampere or 900-ampere deadbreak elbow connectors on 15kV and 25kV class systems.

Estimated time: 1h 30m

1. De-energize Apparatus and Inspect Parts

   De-energize all apparatus in the work area before beginning installation. Inspect all parts for damage, verify their rating, and confirm compatibility with mating parts. Remove any protective shipping covers and replace them with appropriate HV insulated caps or connectors before energizing or submerging the circuit.

2. Assemble Cable and Cut to Length

   Assemble the cable in its final position, ensuring enough slack for elbow removal. If using concentric neutral cable, unwind the concentric neutral wires. Cut the cable 1-3/4 inches (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 inches (610mm) or up to the bent-back concentric neutral wires.

4. Prepare Cable for Connector

   Prepare the cable according to its type (e.g., Unishield, lead sheath, jacketed, or non-jacketed). This involves removing the outer jacket (where applicable) and preparing the cable insulation and shield to the specific dimensions and configurations detailed in the provided diagrams and instructions for your cable type or grounding device.

5. 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.

6. Trim Conductor Insulation

   Remove any protruding cable insulation by cutting it even with the end of the cable adapter. Exercise caution to avoid cutting or nicking the cable adapter or the conductor. Verify that the length of the exposed conductor is between 4-1/4 inches and 4-9/16 inches (108mm-116mm); if not, 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; it must be less than 6-3/8 inches. Crimp the compression lug according to its supplied instructions. Wipe off any excess inhibitor from the lug and cable adapter. Verify the distance from the end of the lug to the cable adapter is between 6-3/8 inches and 7-1/8 inches (162mm-181mm) after crimping; if not, redo the assembly.

8. Install Elbow onto Cable Adapter

   Lubricate the cable adapter and the inside of the elbow's 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.

9. Prepare and Connect Mating Product

   Remove protective caps from both the elbow and the mating part. If the mating part lacks 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 all surfaces remain clean. Push the elbow onto the mating part, aligning the hole in the compression lug with the stud on the mating part. Do not connect or disconnect mating products while energized, and do not energize while disconnected.

10. Connect Opposite Mating Part (if applicable)

    Clean and lubricate the mating part intended 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 specific instructions provided with that mating part.

11. 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. Place the cap on the elbow and push down firmly until it snaps into place.

12. 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 it to form a small loop, taking care not to damage the eye. Connect this wire to ground using a suitable connector. The cable shield must be grounded; follow the instructions supplied with your grounding device or use an alternate method if no device is used. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

13. Perform Final Torque Check (for L-Kits)

    If you are constructing 600-amp L-Kits, ensure that each component is tightened to the specified torque as per the instructions provided with the L-Kit.

14. Remove Voltage Test Point Cap

    Using a hotstick, remove the test point cap. Peel it off at an angle rather than pulling directly in line with the test point assembly.

15. Perform Voltage Test

    Use a suitable sensing device, specifically designed for separable connectors with capacitive test points, to determine if the cable is energized. Follow the manufacturer’s directions for your specific meter. WARNING: The voltage test point is a capacitance device and is not directly connected to the conductor. Do not use conventional voltage measuring equipment. Contamination, moisture, dirt, or using the wrong equipment can lead to a false 'no voltage' indication on an energized elbow. To prevent serious or fatal injury, always treat the elbow as energized until the 'no voltage' test point indication is confirmed by other means.

16. Replace Voltage Test Point Cap

    After confirming voltage detection, clean and lubricate the inside surface of the cap with silicone lubricant and securely replace it on the test point.

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