ABB Installation Products 755LR-L0240 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 on 35kV class systems, including cable preparation, lug crimping, and final connection procedures.

Estimated time: 1h 30m

1. Ensure Safety and Prepare for Installation

   DANGER: All apparatus must be de-energized during installation or removal of parts. Do not touch or move energized products. This product should only be installed by competent personnel trained in high voltage electrical equipment safety practices. Read all instructions before starting. Check the contents of the package to ensure they are complete and undamaged. Verify all components for proper fit with the cable and/or mating products. Have all required tools at hand and maintain cleanliness throughout the procedure.

2. Position and Prepare the Cable

   Position the cable in its final assembled position, ensuring enough slack for adequate clearance to remove the elbows. For 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. Perform Cable Preparation

   Follow the specific cable preparation instructions provided with any grounding device (e.g., 20MA, 21MA) or jacket cable seal (e.g., 600ECS) if being used. For UNISHIELD* or LEAD SHEATH cable, refer to the installation instructions for the 10TL cable shield adapter. For jacketed and non-jacketed cables, remove the outer jacket (where applicable) and prepare the cable according to the detailed diagrams provided in the product documentation, noting the specific measurements 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. The length of the exposed conductor should be between 4-3/8 inches to 4-3/4 inches (111mm-121mm). If the length is outside this range, 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 compression lug. Measure the 'Check Dimension' before crimping; it should be less than 7 inches (178mm). 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. The distance from the end of the compression lug to the cable adapter after crimping should be between 6-7/8 inches to 7-5/8 inches (175mm-194mm). If dimensions are incorrect, 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 is still flush with the tape marker. If not, reposition the cable adapter. Remove the tape marker.

8. Connect to Mating Product

   DO NOT CONNECT OR DISCONNECT MATING PRODUCTS WHILE ENERGIZED. DO NOT ENERGIZE WHILE DISCONNECTED. Remove 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, keeping surfaces clean.

9. Engage Elbow with Mating Part

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

10. Connect Opposite End Mating Product (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. CAUTION: When constructing 600amp L-Kits, ensure each component is tightened to the specified torque per instructions provided with plug connectors.

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 hard until it snaps into place.

12. Ground the Cable Shield and Waterproof

    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 make a small loop, taking care not to damage the eye. Connect this wire to ground using a suitable connector. The shield of the cable 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 from entering the cable.

13. Perform Voltage Test

    The ELASTIMOLD deadbreak elbow connector is equipped with an integral capacitance test point. To use it, remove the test point cap with a hotstick, peeling it off at an angle rather than pulling directly in line. WARNING: The voltage test point is a capacitance device and is NOT directly connected to the conductor. Do not use conventional voltage measuring equipment. Follow the manufacturer’s directions for the specific meter used. Test with a suitable sensing device designed for separable connectors with capacitive test points to determine if the cable is energized. Contamination, moisture, dirt, or using the wrong equipment can provide a false 'no voltage' indication. To prevent serious or fatal injury, treat the elbow as energized until the 'no voltage' test point indication is confirmed by other means. 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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