ABB Installation Products 755LR-K2270 600 Amp, 35kV, 600 Series Deadbreak Elbow (with Insulated Plug, Cap, Stud, Lug and Cable…

Frequently Asked Questions

How to Install 755/775LR Deadbreak Elbow Connectors

This guide details the installation of 755LR and 775LR Deadbreak Elbow Connectors, designed for fully shielded, submersible deadfront cable connections on 35kV class systems. It covers cable preparation, connector assembly, and grounding procedures for 600-ampere or 900-ampere systems.

Estimated time: 1h 30m

1. De-energize and Inspect Apparatus

   Ensure all apparatus in the work area are de-energized before beginning installation or removal of any parts. Do not touch or move energized products. Inspect all connector kit contents and mating parts for damage, correct rating, and compatibility. Failure to follow these instructions will result in damage to the product and serious or fatal injury.

2. Prepare Cable Position and Clean Jacket

   Position the cable in its final assembled location, ensuring enough slack to allow 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. Prepare Cable End

   Refer to the specific instructions for your cable type (e.g., UNISHIELD*, Lead Sheath, Jacketed, Non-Jacketed) for detailed cable preparation, including outer jacket removal and shield connection. For general jacketed/non-jacketed cables, remove the outer jacket (if applicable) and prepare the cable end as shown in the provided diagrams, exposing the cable insulation, semi-con shield, and tape marker at specified lengths (e.g., 10-3/8 inches, 11-3/8 inches, 13-5/8 inches).

4. Install Cable Adapter

   Bevel the end of the cable insulation at a 45-degree angle, approximately 1/4 inch (6mm) back. Thoroughly clean the cable insulation, then lubricate it, always working toward the semi-con shield. Install the cable adapter, small end first, pushing it until it is flush with the edge of the tape marker.

5. Prepare Conductor Length

   Carefully remove the protruding cable insulation by cutting it even with the end of the cable adapter. Ensure you do not cut or nick the cable adapter or the conductor. Verify that the length of the exposed conductor is between 4-3/8 inches to 4-3/4 inches (111mm-121mm). If the length is outside this range, 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 immediately before fully inserting it into the lug. Measure the 'Check Dimension' before crimping (it should be less than 7 inches / 178mm). Crimp the compression lug following the instructions supplied with the lug, locating the first crimp on the end closest to the cable adapter. 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).

7. 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, pushing until it cannot advance further. Confirm that the cable adapter remains flush with the tape marker; reposition it if necessary. Remove the tape marker.

8. Prepare Mating Product Connection

   Remove any 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, ensuring surfaces remain clean. Remember: DO NOT CONNECT OR DISCONNECT MATING PRODUCTS WHILE ENERGIZED. DO NOT ENERGIZE WHILE DISCONNECTED.

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 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 instructions supplied with that specific mating part.

11. Install Insulating Plug 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 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. 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: For 600-amp L-Kits, tighten each component to specified torque per plug connector instructions. The ELASTIMOLD deadbreak elbow connector has an integral capacitance test point. To test for voltage: 1. Remove the test point cap with a hotstick, peeling it off at an angle. 2. WARNING: This 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. Treat the elbow as energized until a 'no voltage' indication is confirmed by other means, as contamination or incorrect equipment can give false readings. 3. 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