ABB Installation Products 755LR-M0330 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 installing 755LR or 775LR deadbreak elbow connectors, designed for fully shielded, fully submersible deadfront cable connections to high voltage apparatus on 35kV class systems.

Estimated time: 2h

1. Prepare for Installation and Ensure Safety

   DANGER: All apparatus must be de-energized during installation or removal of part(s). Do not touch or move energized products in the work area. This product should be installed only by competent personnel trained in good safety practices involving high voltage electrical equipment. Inspect all parts for damage, rating, and compatibility with mating parts. Check the package contents to ensure they are complete and undamaged. Read the entire installation instructions before starting and have all required tools at hand, maintaining cleanliness throughout the procedure.

2. Position and Cut 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” (45mm) from the centerline of the mating product. Clean the outer jacket of the cable for a distance of 24” (610mm).

3. Prepare Cable (Jacketed/Non-Jacketed)

   Follow the specific cable preparation steps based on your cable type. If using a 20MA or 21MA grounding device or 600ECS Jacket Cable Seal, refer to their instructions for outer jacket removal, shield connection, and grounding. For UNISHIELD* or LEAD SHEATH cable, a 10TL cable shield adapter is required; refer to its installation instructions. For jacketed and non-jacketed cable, remove the outer jacket (if applicable) and prepare the cable as shown in the diagrams for non-jacketed concentric neutral, jacketed shield wires, jacketed flat metallic tape shield, jacketed fabric tape shield, or jacketed longitudinally corrugated shield, marking the tape at 10-3/8” (264mm), 11-3/8” (289mm), and 13-5/8” (340mm).

4. Install Cable Adapter

   Bevel the end of the cable insulation at a 45-degree angle, approximately 1/4” (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 Conductor 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 should be between 4-3/8” to 4-3/4” (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 and immediately fully insert it into the compression lug. Measure the 'Check Dimension' before crimping; it should be less than 7” (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” to 7-5/8” (175mm-194mm). If dimensions are incorrect, redo the assembly.

7. Install Elbow onto Cable Adapter

   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. Prepare Mating Products

   DANGER: DO NOT CONNECT OR DISCONNECT MATING PRODUCTS WHILE ENERGIZED. DO NOT ENERGIZE WHILE DISCONNECTED. Remove any protective shipping covers from the elbow and the mating part, replacing them with appropriate HV insulated caps or connectors if submerging or energizing. Hand tighten the threaded stud supplied with the elbow into the mating part if the mating part is not equipped with a stud. Clean and lubricate both the elbow and the mating part with the supplied lubricant, keeping surfaces clean.

9. 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.

10. Connect Opposite End of Elbow (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 and place it on the elbow. Push down hard until the cap snaps into place.

12. Ground the Cable Shield

    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 according to the instructions supplied with the grounding device. If no grounding device is used, the shield must be grounded through an alternate method. It is also recommended to waterproof the cable jacket at this point to prevent moisture from entering the cable.

13. Perform Voltage Test (Optional but Recommended)

    The ELASTIMOLD deadbreak elbow connector is equipped with an integral capacitance test point. To use it: 1. Remove the test point cap with a hotstick, peeling it off at an angle. 2. 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 and follow its manufacturer’s directions. Contamination, moisture, or incorrect equipment can give a false 'no voltage' reading. Treat the elbow as energized until the 'no voltage' indication is confirmed by other means to prevent serious or fatal injury. 3. 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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