ABB Installation Products 755LR-L0300 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 installation and connection of 755LR and 775LR Deadbreak Elbow Connectors on 35kV class systems, including cable preparation, crimping, and mating procedures. Ensure all apparatus are de-energized before beginning installation.

Estimated time: 2h

1. Safety First & Initial Inspection

   Ensure all apparatus are de-energized before starting. Inspect all package contents for completeness and damage. Verify all components fit properly with the cable and mating products. Have all required tools ready and maintain cleanliness throughout the procedure. This product must be installed by competent personnel trained in high voltage electrical safety practices.

2. Position Cable and Cut

   Position the cable in its final assembled location, allowing sufficient slack for elbow removal. If using concentric neutral cable, unwind the neutral wires. Precisely cut the cable 1-3/4” (45mm) from the centerline of the mating product.

3. Clean Cable Jacket

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

4. Prepare Cable for Termination

   Remove the outer jacket (if applicable) and prepare the cable insulation and semi-con shield to the specific dimensions shown in the diagrams 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 provided illustrations for precise measurements and tape marker placement.

5. Install Cable Adapter

   Bevel the end of the cable insulation at a 45-degree angle, approximately 1/4” (6mm) back. Thoroughly clean and 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.

6. Expose Conductor

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

7. 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. Measure the 'Check Dimension' (which must be less than 7”/178mm) before crimping. Crimp the compression lug according to the instructions supplied with the lug. After crimping, wipe off 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” to 7-5/8” (175mm-194mm); if not, redo the assembly.

8. Install Elbow

   Lubricate the cable adapter and the inside of the elbow cable entrance. Install the elbow onto the cable adapter by pushing it until it cannot advance further. Confirm the cable adapter remains flush with the tape marker. Reposition the cable adapter if necessary, then remove the tape marker.

9. Prepare and Connect to Mating Product

   Remove any protective caps from both the elbow and the mating part. If the mating part lacks a stud, hand tighten the threaded stud (supplied with the elbow) into it. Clean and lubricate both the elbow and the mating part with the provided lubricant, ensuring all surfaces remain clean. WARNING: DO NOT CONNECT OR DISCONNECT MATING PRODUCTS WHILE ENERGIZED. DO NOT ENERGIZE WHILE DISCONNECTED.

10. Push Elbow onto Mating Part

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

11. 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 to the specifications provided in its own instructions.

12. 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 onto the elbow and push down firmly until it snaps securely into place.

13. Ground the Cable Shield

    Insert one end of a grounding wire (minimum No. 14 AWG Copper) through the grounding eye and twist it 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; refer to instructions for your grounding device or use an alternate method. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

14. Perform Voltage Test (Recommended)

    CAUTION: For 600amp L-Kits, ensure all components are tightened to the specified torque per plug connector instructions. To test for voltage, remove the test point cap using a hotstick, peeling it off at an angle. WARNING: The voltage test point is a capacitance device and is NOT directly connected to the conductor. Use only a suitable sensing device designed for separable connectors with capacitive test points, following its manufacturer’s directions. Do not use conventional voltage measuring equipment. Treat the elbow as energized until a 'no voltage' indication is confirmed by other means, as contamination or incorrect equipment can lead to false readings. After testing, clean and lubricate the inside surface of the cap with silicone lubricant and replace it securely on the test point.

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