ABB Installation Products 755LR-J0300-S 600 Amp, 35kV, 600 Series Deadbreak Elbow (with Insulated Plug, Cap, Stud, Lug and Cable…

Frequently Asked Questions

How to Install 755LR/775LR Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe installation and setup of 755LR and 775LR Deadbreak Elbow Connectors on 35kV class systems, including cable preparation, lug crimping, and connection to mating apparatus.

Estimated time: 2h

1. Prepare the Work Area and Inspect Components

   Ensure all apparatus is de-energized before beginning installation. Inspect all parts from the connector kit for damage, proper rating, and compatibility with mating parts. Remove any protective shipping covers and replace with appropriate HV insulated caps or connectors if the circuit will be submerged or energized later. Have all required tools and supplies at hand.

2. Position and Prepare the Cable

   Position the cable in its final assembled location, ensuring enough slack for elbow removal. For 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 jacket of the cable for a distance of 24 inches (610mm).

3. Perform Cable Shield Preparation

   Prepare the cable shield according to its type. If using a 20MA/21MA grounding device or 600ECS Jacket Cable Seal, refer to their specific instructions. For UNISHIELD* or LEAD SHEATH cable, use a 10TL cable shield adapter and follow its instructions. For jacketed or non-jacketed cables, remove the outer jacket (if applicable) and prepare the cable as shown in the diagrams, ensuring correct dimensions for cable insulation, semi-con shield, and tape marker locations.

4. Install the 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 toward the semi-con shield. Install the cable adapter, small end first, until it is flush with the edge of the tape marker.

5. Prepare the Conductor

   Remove the protruding cable insulation by cutting it even with the end of the cable adapter. Be careful not to cut or nick the cable adapter or the conductor. Verify the exposed conductor length is between 4-3/8 inches to 4-3/4 inches (111mm-121mm); if not, redo the assembly.

6. Crimp the Compression Lug

   For copper conductors, fully insert the conductor into the compression lug. For aluminum conductors, wire brush the conductor immediately before fully inserting it into the lug. Measure the 'Check Dimension' before crimping; it must be less than 7 inches (178mm). Crimp the compression lug following the instructions provided with the lug. After crimping, wipe all excess inhibitor from the lug and cable adapter surface. Verify the distance from the end of the compression lug to the cable adapter is between 6-7/8 inches to 7-5/8 inches (175mm-194mm); if not, redo the assembly.

7. Install the Elbow

   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.

8. Prepare Mating Products

   WARNING: DO NOT CONNECT OR DISCONNECT MATING PRODUCTS WHILE ENERGIZED. DO NOT ENERGIZE WHILE DISCONNECTED. Remove protective caps from both 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, keeping surfaces clean.

9. Connect the Elbow to the Mating Part

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

10. Secure the Opposite End of the 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 that specific mating part.

11. 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 firmly until it snaps into place.

12. Ground the Cable Shield

    Insert one end of a grounding wire (at least 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 or use an alternate method. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

13. Perform Voltage Test

    CAUTION: When constructing 600amp L-Kits, tighten each component to specified torque per plug connector instructions. To test for voltage, remove the test point cap with a hotstick, peeling it off at an angle. WARNING: The voltage test point is a capacitance device, not directly connected to the conductor. Do not use conventional voltage measuring equipment. Use a suitable sensing device designed for capacitive test points and follow its manufacturer's directions. Contamination, moisture, or incorrect equipment can give a false 'no voltage' indication. Treat the elbow as energized until the 'no voltage' indication is confirmed by other means to prevent serious or fatal injury. After testing, clean and lubricate the inside surface of the cap with silicone lubricant and replace it on the test point.

Frequently Asked Questions about ABB - Installation Products