755LR-L0260

Frequently Asked Questions

How to Install 755LR/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. Ensure all apparatus are de-energized before beginning.

Estimated time: 2h

1. Ensure Safety and Inspect Components

   DANGER: De-energize all apparatus before installation or removal. Do not touch or move energized products. This product must be installed only by competent personnel trained in high voltage electrical equipment safety practices. Inspect all package contents and components for completeness, damage, proper rating, and compatibility with mating parts. Remove any protective shipping covers and replace with appropriate HV insulated caps or connectors before submerging or energizing.

2. Position and Cut Cable

   Position the cable in its final assembled position, ensuring enough slack for elbow removal. For concentric neutral cable, unwind the concentric neutral wires. Cut the cable 1-3/4 inches (45mm) from the centerline of the mating product.

3. Clean Cable Outer Jacket

   Clean the outer jacket of the cable for a distance of 24 inches (610mm) from the cut end.

4. Prepare Cable Insulation and Shield

   Follow the specific instructions for your cable type. If using a 20MA or 21MA grounding device or 600ECS Jacket Cable Seal, refer to their instructions. For UNISHIELD* or LEAD SHEATH cable, refer to the 10TL cable shield adapter instructions. For jacketed and non-jacketed cables, remove the outer jacket (if applicable) and prepare the cable insulation and semi-con shield according to the provided diagrams, using the specified dimensions (e.g., 10-3/8in, 11-3/8in, 13-5/8in for various shield types).

5. Bevel Insulation 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.

6. Expose Conductor and Verify Length

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

7. Install and 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 compression 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. After crimping, wipe all excess inhibitor from the lug and cable adapter surface. The distance from the end of the compression lug to the cable adapter must be between 6-7/8 inches to 7-5/8 inches (175mm-194mm). Redo if not within range.

8. 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 until it cannot advance further. Ensure the cable adapter remains flush with the tape marker; reposition if necessary. Remove the tape marker.

9. Prepare Mating Products for Connection

   DANGER: 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 surfaces remain clean.

10. Connect Elbow to 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.

11. Connect Opposite End (if applicable)

    If connecting the opposite end of the elbow (e.g., for splicing or tapping), clean and lubricate the mating part for that end. Insert the 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.

12. 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.

13. 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 make 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 according to the instructions supplied with the grounding device, or through an alternate method if no device is used. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

14. Perform Voltage Test

    CAUTION: For 600amp L-Kits, tighten each component to specified torque per plug connector instructions. 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 made for capacitive test points. Contamination, moisture, or incorrect equipment can give a false 'no voltage' indication. Treat the elbow as energized until confirmed by other means. Remove the test point cap with a hotstick, peeling it off at an angle. Test for voltage with the suitable sensing device. 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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