ABB Installation Products 755LR-Q0410 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 on 35kV class systems. These connectors enable fully shielded, submersible cable connections and facilitate splicing or tapping of 600-ampere or 900-ampere systems.

Estimated time: 2h

1. De-energize Apparatus and Inspect Parts

   Before beginning, ensure all apparatus in the work area are de-energized. Do not touch or move energized products. Inspect all components of the 755/775LR connector kit for damage, proper rating, and compatibility with mating parts. Verify that all required tools and supplies are at hand and maintain cleanliness throughout the procedure.

2. Position Cable and Prepare for Cutting

   Position the cable in its final assembled location, ensuring sufficient slack for elbow removal. If using concentric neutral cable, unwind the concentric neutral wires. Measure and cut the cable 1-3/4 inches (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 inches (610mm) from the cut end.

4. Prepare Cable Insulation and Shield

   Prepare the cable by removing the outer jacket, semi-con shield, and cable insulation according to the specific cable type (e.g., non-jacketed concentric neutral, jacketed shield wires, flat metallic tape shield, fabric tape shield, or longitudinally corrugated shield) and the dimensions provided in the installation instructions. Refer to any specific instructions for grounding devices or cable shield adapters if applicable.

5. Bevel Insulation 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 lubricate the cable insulation, 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 Insulation and Verify Conductor Length

   Carefully remove any 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. Verify that the exposed conductor length is between 4-3/8 inches (111mm) and 4-3/4 inches (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 immediately before fully inserting it into the compression lug. Measure the 'Check Dimension' before crimping, ensuring it is less than 7 inches (178mm). Crimp the compression lug following the specific crimping instructions provided 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 inches (175mm) and 7-5/8 inches (194mm).

8. Lubricate and Install Elbow

   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. Confirm the cable adapter remains flush with the tape marker; reposition if necessary. Remove the tape marker.

9. Prepare and Connect Elbow to Mating Part

   Remove any protective caps from 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 thoroughly. Push the elbow onto the mating part, carefully aligning the hole in the compression lug with the stud on the mating part. WARNING: Do not connect or disconnect mating products while energized, and do not energize while disconnected.

10. Connect Opposite Mating Part (if applicable)

    If connecting an opposite end, clean and lubricate the mating part. Insert this mating part into the elbow, engage the threads, and hand tighten. Torque the mating part according to its specific instructions.

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 firmly until it snaps into place.

12. Ground the Cable Shield

    Insert one end of a No. 14 AWG Copper wire (or equivalent 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. Ensure the cable shield is properly grounded, either via a grounding device or an alternate method. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

13. Perform Voltage Test and Replace Cap

    CAUTION: If constructing 600-amp L-Kits, tighten each component to the specified torque per plug connector instructions. To test for voltage, remove the test point cap from the elbow with a hotstick, peeling it off at an angle. WARNING: The voltage test point is a capacitance device, not directly connected to the conductor. Use only a suitable sensing device designed for capacitive test points, following its manufacturer's directions. Do not use conventional voltage measuring equipment, as contamination 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 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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