ABB Installation Products 755LR-K0240 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 755/775LR Deadbreak Elbow Connectors, designed for fully shielded, submersible cable connections to high voltage apparatus on 35kV class systems.

1. Prepare for Installation and De-energize Apparatus

   DANGER: All apparatus must be de-energized during installation or removal of parts. Do not touch or move energized products in the work area. Inspect all package contents and components for completeness, damage, proper rating, and compatibility with mating products. Read the entire installation instructions before starting and ensure all required tools are at hand, maintaining cleanliness throughout the procedure.

2. Position and Clean Cable

   Position the cable in its final assembled location, ensuring enough slack for adequate clearance to remove the elbows. 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. Clean the outer jacket of the cable for a distance of 24 inches (610mm).

3. Prepare Cable Jacket and Shield

   Prepare the cable by removing the outer jacket (if applicable) and shield according to the specific dimensions and diagrams provided for your cable type (e.g., non-jacketed concentric neutral, jacketed shield wires, flat metallic tape shield, fabric tape shield, or longitudinally corrugated shield). Refer to the installation instructions supplied with any grounding devices or cable shield adapters if they are being used.

4. Bevel, Clean, Lubricate, and 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 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 Cable Insulation

   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. Verify that the exposed conductor length is between 4-3/8 inches to 4-3/4 inches (111mm-121mm). If the length is outside this range, redo the assembly.

6. Install 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 inches (178mm). If not, redo the assembly. Crimp the compression lug following 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 6-7/8 inches to 7-5/8 inches (175mm-194mm). If not, redo the assembly.

7. Lubricate and 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. Ensure the cable adapter remains flush with the tape marker; if not, reposition the cable adapter. Remove the tape marker.

8. Prepare Mating Products and Stud

   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. 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 all surfaces remain clean.

9. Connect Elbow to 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. Connect Opposite End of Elbow (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 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 onto the elbow and push down firmly until it snaps securely into place.

12. 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 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 the 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 Voltage Test

    CAUTION: When constructing 600amp L-Kits, ensure each component is tightened to the specified torque per the instructions provided with plug connectors. To test for voltage, remove the test point cap with a hotstick, peeling it off at an angle rather than pulling directly. WARNING: The voltage test point is a capacitance device and is not directly connected to the conductor. Do not use conventional voltage measuring equipment. Use a suitable sensing device designed for separable connectors with capacitive test points, following the manufacturer’s directions. Contamination, moisture, dirt, or incorrect 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, clean and lubricate the inside surface of the cap with silicone lubricant and replace it on the test point.

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