ABB Installation Products 755LR-N0380 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, designed for 35kV class systems to create fully shielded, submersible cable connections.

Estimated time: 2h

1. Perform Initial Safety Checks and Inspect Components

   DANGER: All apparatus must be de-energized during installation or removal of parts. Inspect the connector kit contents to ensure they are complete and undamaged. Verify all components are compatible with the cable and any mating products. Read all installation instructions thoroughly before beginning.

2. Position Cable and Make Initial Cut

   Position the cable so it is located in its final assembled position, ensuring enough slack to provide adequate clearance for removing the elbows. If applicable, unwind the concentric neutral wires. Cut the cable 1-3/4” (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” (610mm) from the cut end.

4. Prepare Cable According to Type

   Follow the specific cable preparation steps that apply to your cable type. If using a 20MA or 21MA grounding device or 600ECS Jacket Cable Seal, refer to their supplied instructions. 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, ensuring precise dimensions for cable insulation, semi-con shield, and tape marker (e.g., 10-3/8” (264mm) for insulation, 11-3/8” (289mm) for semi-con shield, 13-5/8” (340mm) for tape marker).

5. Install Cable Adapter

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

   Carefully remove the protruding cable insulation by cutting it even with the end of the cable adapter. Do not 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 not, 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 and immediately fully insert it into the compression lug. Measure the “Check Dimension” before crimping; this dimension 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).

8. 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 the elbow cannot advance further. Make sure the cable adapter is still flush with the tape marker; if not, reposition the cable adapter. Remove the tape marker.

9. Connect to Mating Product

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

10. Connect Opposite End (If Applicable)

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

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

    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, ensuring 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, or through an alternate method if no grounding device is used. It is also recommended to waterproof the jacket of the cable at this point to prevent moisture from entering the cable.

13. Perform Voltage Test (Safety Critical)

    CAUTION: When constructing 600amp L-Kits, be sure to tighten each component to the specified torque per instructions provided with plug connectors. To perform a voltage test, remove the test point cap with a hotstick, peeling it off at an angle rather than pulling directly in line with the test point assembly. 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 a suitable sensing device made for use with 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. Treat the elbow as energized until the “no voltage” test point indication is confirmed by other means to prevent serious or fatal injury. After voltage detection, clean and lubricate the inside surface of the cap with silicone lubricant and replace it on the test point.

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