ABB Installation Products 775LR-J2230 900 Amp, 35kV, 600 Series Elbow with insulated plug, cap, stud, lug and cable adapter.…

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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, including cable preparation and connection to mating apparatus. DANGER: All apparatus must be de-energized during installation.

Estimated time: 1h 30m

1. Position and Cut Cable

   DANGER: Ensure all apparatus is de-energized during installation or removal of parts. Position the cable in its final assembled position, allowing enough slack to remove elbows. For concentric neutral cable, unwind the concentric neutral wires. Cut the cable 1-3/4” (45mm) from the centerline of the mating product.

2. Clean Cable Outer Jacket

   Clean the outer jacket of the cable for a distance of 24” (610mm).

3. Prepare Cable Shield and Jacket

   Follow the specific cable preparation instructions based on your cable type. If using a 20MA or 21MA grounding device or 600ECS Jacket Cable Seal, refer to their instructions. For UNISHIELD* or LEAD SHEATH cable, use a 10TL cable shield adapter and 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 semi-con shield, cable insulation, and tape markers.

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 exposed conductor length must be between 4-3/8” to 4-3/4” (111mm-121mm); otherwise, redo the assembly.

6. Install 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 compression lug. Measure the “Check Dimension” before crimping; it should be less than 7” (178mm). Crimp the compression lug according to the instructions supplied with the lug. After crimping, wipe all excess inhibitor from the compression lug and cable adapter surface. The distance from the end of the compression lug to the cable adapter should be between 6-7/8” to 7-5/8” (175mm-194mm); otherwise, 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. Verify that the cable adapter is still flush with the tape marker; if not, reposition the cable adapter. Remove the tape marker.

8. Prepare Mating Products for Connection

   DANGER: Do not connect or disconnect mating products while energized, and do not energize while disconnected. Remove any protective caps from the elbow and the mating part. If the mating part is not equipped with 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.

9. 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.

10. Connect Opposite Mating Part

    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.

11. Install Insulating Plug or Voltage Detection Cap

    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 cable shield must be grounded; follow instructions supplied with any grounding device or use an alternate method. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

13. Perform Voltage Test and Secure Test Point

    The ELASTIMOLD deadbreak elbow connector has an integral capacitance test point. To test for voltage: 1. Remove the test point cap with a hotstick, peeling it off at an angle. 2. WARNING: This 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 and follow its manufacturer’s directions. Treat the elbow as energized until a 'no voltage' indication is confirmed by other means, as contamination or incorrect equipment can give false readings. 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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