ABB Installation Products 755LR-J0230 600 Amp, 35kV, 600 Series Deadbreak Elbow (with Insulated Plug, Cap, Stud, Lug and Cable…

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How to Install 755/775LR Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe and proper installation of 755LR and 775LR Deadbreak Elbow Connectors. These connectors create fully shielded, submersible deadfront cable connections for high voltage apparatus and enable splicing or tapping of 600-ampere or 900-ampere, 35kV class systems.

Estimated time: 2h

1. Position Cable and Prepare Neutral Wires

   DANGER: All apparatus must be de-energized during installation or removal of parts. Position the cable in its final assembled position, ensuring enough slack for elbow removal. For concentric neutral cable, unwind the concentric neutral wires. Cut the cable 1-3/4” (45mm) from the center line of the mating product.

2. Clean Cable Outer Jacket

   Clean the outer jacket of the cable for a distance of 24” (610mm) from the cut end.

3. Prepare the Cable for Connection

   Remove the outer jacket (if applicable) and prepare the cable according to its specific type (e.g., non-jacketed concentric neutral, jacketed shield wires, flat metallic tape shield, fabric tape shield, or longitudinally corrugated shield). Refer to the provided diagrams for precise measurements for removing the outer jacket, semi-con shield, and cable insulation. For UNISHIELD* or LEAD SHEATH cable, use a 10TL cable shield adapter and its instructions. If using a 20MA or 21MA grounding device or 600ECS Jacket Cable Seal, refer to their specific installation instructions for jacket removal, shield connection, and grounding.

4. Bevel 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. Trim Insulation and Verify Conductor Length

   Remove the 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. The length of the exposed conductor must be between 4-3/8” to 4-3/4” (111mm-121mm). If the length is outside this range, redo the assembly.

6. Attach and 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 should be less than 7” (178mm). Crimp the compression lug following its supplied instructions. Wipe all excess inhibitor from the lug and cable adapter surface after crimping. The distance from the end of the compression lug to the cable adapter after crimping must be between 6-7/8” to 7-5/8” (175mm-194mm). Redo assembly if dimensions are not met.

7. Lubricate and Install Elbow

   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. If not, reposition the cable adapter. Remove the tape marker.

8. Prepare Elbow and Mating Part

   WARNING: DO NOT CONNECT OR DISCONNECT MATING PRODUCTS WHILE ENERGIZED. DO NOT ENERGIZE WHILE DISCONNECTED. Remove any protective caps from the elbow and the mating part. Hand tighten the threaded stud supplied with the elbow into the mating part, if the mating part is not already equipped with a stud. Clean and lubricate both the elbow and the mating part with the supplied lubricant, ensuring surfaces remain clean.

9. Connect Elbow to Apparatus

   Push the elbow onto the mating part, carefully aligning the hole in the compression lug with the stud on the mating part.

10. Connect Second 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 specific instructions supplied with that mating part.

11. Install Insulating Plug and Cap (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 securely 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 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 instructions supplied with any grounding device used, or employ an alternate grounding method if no device is present. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

13. Perform Voltage Test and Reinstall Cap

    CAUTION: When constructing 600A L-Kits, tighten each component to specified torque per plug connector instructions. The ELASTIMOLD deadbreak elbow connector has an integral capacitance test point to check if the circuit is energized. To use, remove the test point cap with a hotstick, peeling it off at an an angle. WARNING: This is a capacitance device, not directly connected to the conductor. Do not use conventional voltage measuring equipment. Use a suitable sensing device as per its manufacturer’s directions. Contamination or incorrect equipment can give a false 'no voltage' reading. Treat the elbow as energized until confirmed otherwise to prevent serious injury. After testing, clean, lubricate with silicone, and replace the cap.

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