ABB Installation Products 755LR-J2260 600 Amp, 35kV, 600 Series Deadbreak Elbow (with Insulated Plug, Cap, Stud, Lug and Cable…

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How to Install Elastimold 755LR/775LR Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe installation and connection of Elastimold 755LR and 775LR Deadbreak Elbow Connectors on 35kV class systems. Ensure all apparatus are de-energized before beginning any work.

Estimated time: 2h

1. Ensure Safety and Inspect Parts

   DANGER: All apparatus must be de-energized during installation or removal. Inspect all parts for damage, correct rating, and compatibility with mating components. Remove any protective shipping covers and replace them with appropriate HV insulated caps or connectors before energizing or submerging the circuit.

2. Position and Clean Cable

   Position the cable in its final assembled location, ensuring enough slack for elbow removal. If using concentric neutral cable, unwind the neutral wires. Cut the cable 1-3/4” (45mm) from the centerline of the mating product. Thoroughly clean the outer jacket of the cable for a distance of 24” (610mm).

3. Prepare Cable Ends

   Follow specific instructions for any grounding devices (e.g., 20MA, 21MA) or cable shield adapters (e.g., 10TL) if applicable. For jacketed and non-jacketed cables, remove the outer jacket (if present) and prepare the cable according to the provided diagrams, ensuring precise measurements for insulation, semi-con shield, and tape marker locations (e.g., 10-3/8”, 11-3/8”, 13-5/8” from the cable end).

4. 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.

5. Prepare Conductor

   Carefully remove any protruding cable insulation by cutting it even with the end of the cable adapter. Ensure not to cut or nick the cable adapter or the conductor. Verify that the length of the exposed conductor is between 4-3/8” to 4-3/4” (111mm-121mm); if not, redo the assembly.

6. 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' (must be less than 7”/178mm) before crimping. Crimp the compression lug following its supplied instructions. Wipe off all excess inhibitor and verify the distance from the end of the lug to the cable adapter is 6-7/8” to 7-5/8” (175mm-194mm) after crimping.

7. Install 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. Confirm the cable adapter remains flush with the tape marker; reposition if necessary. Remove the tape marker.

8. Prepare and Connect Mating Products

   WARNING: Do not connect or disconnect mating products while energized, and do not energize while disconnected. Remove protective caps from both the elbow and the mating part. Hand tighten the threaded stud (if supplied with the elbow) into the mating part if it is not already equipped with one. Clean and lubricate both the elbow and the mating part with the supplied lubricant. Push the elbow onto the mating part, aligning the hole in the compression lug with the stud.

9. Connect Opposite End (if applicable)

   If connecting the opposite end of the elbow, clean and lubricate its mating part. 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.

10. Install Insulating Plug (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 securely into place.

11. Ground the Cable Shield

    Insert one end of a grounding 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. Ensure the cable shield is properly grounded, either through a dedicated grounding device or an alternate method. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

12. Perform Voltage Test

    CAUTION: For 600A L-Kits, ensure all components are tightened to specified torque. 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. Use only a suitable sensing device designed for capacitive test points; do not use conventional voltage measuring equipment. Treat the elbow as energized until a '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.

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