ABB Installation Products 755LR-Q0400 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 and 775LR Deadbreak Elbow Connectors, including cable preparation, component assembly, and connection to high voltage apparatus. DANGER: All apparatus must be de-energized during installation. This product should only be installed by competent personnel trained in high voltage electrical equipment safety.

Estimated time: 1h 30m

1. Inspect Components and Prepare Workspace

   Inspect all parts for damage, proper rating, and compatibility with mating components. Verify the package contents are complete and undamaged. Ensure all components fit correctly with the cable and/or mating products. Have all required tools at hand and maintain cleanliness throughout the procedure.

2. Position and Cut Cable

   Position the cable in its final assembled location with enough slack for elbow removal. For concentric neutral cable, unwind the neutral wires. 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 for a distance of 24” (610mm).

4. Prepare Cable According to Type

   Prepare the cable according to its type. If using a 20MA/21MA grounding device or 600ECS Jacket Cable Seal, follow their instructions. For UNISHIELD or LEAD SHEATH cable, use a 10TL cable shield adapter and follow its instructions. For jacketed and non-jacketed cables, remove the outer jacket (if applicable) and prepare the cable as shown in the diagrams, ensuring correct dimensions for insulation, semi-con shield, and tape markers.

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, 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

   Remove the protruding cable insulation by cutting it even with the end of the cable adapter. Ensure not to cut or nick the cable adapter or the conductor. The exposed conductor length must be between 4-3/8” to 4-3/4” (111mm-121mm); otherwise, 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' (must be less than 7”/178mm) before crimping. Crimp the compression lug following its supplied instructions. Wipe off any excess inhibitor. After crimping, the distance from the end of the lug to the cable adapter should be 6-7/8” to 7-5/8” (175mm-194mm); otherwise, 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 until it cannot advance further. Verify the cable adapter is still 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 the elbow and the mating part. Hand tighten the threaded stud (supplied with the elbow) into the mating part if it's not already equipped. Clean and lubricate both the elbow and the mating part with the supplied lubricant, keeping surfaces clean.

10. Connect Elbow to Mating Part

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

11. Connect Opposite End (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 its supplied 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 and place it on the elbow. Push down firmly until the cap snaps into place.

13. Ground the Cable Shield

    Insert one end of a wire (at least No. 14 AWG Copper ampacity) through the grounding eye and twist 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 grounding device instructions 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: For 600A L-Kits, torque components as per plug instructions. Remove the test point cap with a hotstick, peeling at an angle. WARNING: This is a capacitance device; do not use conventional voltage meters. Use a suitable sensing device designed for capacitive test points and follow its directions. Treat the elbow as energized until a 'no voltage' indication is confirmed by other means to prevent serious injury. Clean and lubricate the cap's inner surface with silicone lubricant, then replace it on the test point.

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