ABB Installation Products 755LR-M0300 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, ensuring fully shielded and submersible cable connections. Follow all safety warnings for high voltage equipment.

Estimated time: 2h

1. De-energize Apparatus and Inspect Components

   DANGER: All apparatus must be de-energized during installation or removal of parts. Do not touch or move energized products. Inspect all package contents and components for damage, proper rating, and compatibility with mating parts before beginning installation. Ensure all required tools are at hand and maintain cleanliness throughout the procedure.

2. Position and Cut the Cable

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

3. Clean the Cable Outer Jacket

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

4. Prepare Cable Insulation and Shield

   Prepare the cable according to its type (e.g., non-jacketed concentric neutral, jacketed shield wires, flat metallic tape shield, fabric tape shield, or longitudinally corrugated shield). Remove the outer jacket (if applicable) and prepare the cable insulation and semi-con shield to the specific dimensions indicated in the product's detailed diagrams (e.g., 10-3/8", 11-3/8", 13-5/8" from the cable end).

5. 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 towards the semi-con shield. Install the cable adapter, small end first, until it is flush with the edge of the tape marker.

6. Trim Cable Insulation and Verify Conductor Length

   Remove any protruding cable insulation by cutting it even with the end of the cable adapter. Exercise caution not to cut or nick the cable adapter or the conductor. The exposed conductor length must be between 4-3/8 inches to 4-3/4 inches (111mm-121mm). If not, redo the assembly.

7. Prepare Conductor 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 lug. Measure the 'Check Dimension' (distance from lug end to cable adapter) before crimping; it should be less than 7 inches (178mm). Crimp the compression lug according to its supplied instructions. Wipe off any excess inhibitor from the lug and cable adapter surface. After crimping, the distance from the end of the compression lug to the cable adapter should be between 6-7/8 inches to 7-5/8 inches (175mm-194mm). If not, redo the assembly.

8. Lubricate and 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. Verify that the cable adapter remains flush with the tape marker; reposition if necessary. Remove the tape marker.

9. Prepare Mating Products

   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. If the mating part lacks 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.

10. 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.

11. Connect Opposite End Mating Part (if applicable)

    If connecting another mating part to the opposite end of the elbow, clean and lubricate its mating surface. 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.

12. Install Insulating Plug or Voltage Detection 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.

13. Ground Cable Shield and Waterproof Jacket

    Insert one end of a No. 14 AWG Copper wire (or equivalent ampacity) 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; follow instructions for any grounding device used, or an alternate method. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

14. Perform Voltage Test

    CAUTION: When constructing 600A L-Kits, tighten each component to specified torque per plug connector instructions. The elbow connector has an integral capacitance test point. Remove the test point cap with a hotstick, peeling it off at an angle. 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 designed for capacitive test points, following its manufacturer's directions, to determine if the cable is energized. Contamination, moisture, dirt, or incorrect equipment can give a false 'no voltage' indication. Treat the elbow as energized until the 'no voltage' indication is confirmed by other means to prevent serious or fatal injury. 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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