ABB Installation Products 775LR-J2240 900 Amp, 35kV, 600 Series Elbow with insulated plug, cap, stud, lug and cable adapter.…

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How to Install 755LR/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, lug crimping, and connection to mating parts.

Estimated time: 2h

1. Ensure Safety and Inspect Components

   DANGER: De-energize all apparatus in the work area before beginning installation. Do not touch or move energized products. This installation must only be performed by competent personnel trained in high voltage electrical safety practices and in accordance with all applicable work rules. Inspect all package contents to ensure they are complete and undamaged. Verify all components for proper fit with the cable and mating products. Remove any protective shipping covers and replace with appropriate HV insulated caps or connectors if the circuit will be submerged or energized.

2. Position and Cut the Cable

   Position the cable in its final assembled location, ensuring enough slack to allow for elbow removal. For concentric neutral cable, unwind the concentric neutral wires. Cut the cable 1-3/4 inches (45mm) from the centerline of the mating product.

3. Clean the Cable Jacket

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

4. Prepare the Cable

   Prepare the cable according to the specific type (e.g., non-jacketed concentric neutral, jacketed shield wires, flat metallic tape shield, fabric tape shield, or longitudinally corrugated shield) as detailed in the provided diagrams. This involves removing the outer jacket (if applicable) and preparing the cable insulation and semi-con shield to the specified dimensions. If using a 20MA or 21MA grounding device, 600ECS Jacket Cable Seal, or 10TL cable shield adapter, refer to their respective installation instructions for cable preparation.

5. Install the Cable Adapter

   Bevel the end of the cable insulation at a 45-degree angle, approximately 1/4 inch (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.

6. Expose the Conductor

   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 inches (111mm) and 4-3/4 inches (121mm). If not, redo the assembly.

7. Crimp the 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 must be less than 7 inches (178mm). Crimp the compression lug according to the instructions supplied with the lug, starting the first crimp on the end closest to the cable adapter. 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 must be between 6-7/8 inches (175mm) and 7-5/8 inches (194mm). If not, redo the assembly.

8. Install the Elbow

   Lubricate the cable adapter and the inside of the elbow's cable entrance. Install the elbow onto the cable adapter until it cannot advance further. Verify that the cable adapter remains flush with the tape marker; reposition if necessary. Remove the tape marker.

9. Prepare Mating Products

   WARNING: Do not connect or disconnect mating products while energized, and do not energize while disconnected. Remove protective caps from both 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 all surfaces remain clean.

10. 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.

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 the instructions supplied with that specific mating part.

12. 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.

13. Ground the Cable Shield

    Insert one end of a wire (with ampacity at least equivalent to No. 14 AWG Copper) 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 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.

14. Perform Voltage Test and Finalize

    CAUTION: When constructing 600amp L-Kits, ensure each component is tightened to the specified torque per the plug connector instructions. To perform a voltage test using the integral capacitance test point: 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 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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