ABB Installation Products 775LR-J2260 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 apparatus.

Estimated time: 1h 30m

1. Perform Initial Safety Checks and Inspections

   DANGER: De-energize all apparatus in the work area before starting installation or removal. Do not touch or move energized products. Inspect all parts for damage, proper rating, and compatibility with mating parts. Ensure all required tools are at hand and maintain cleanliness throughout the procedure. If the product is supplied with protective shipping covers, remove them and replace with appropriate HV insulated caps or connectors before submerging or energizing the circuit.

2. Prepare the Cable for Connection

   Position the cable in its final assembled position, ensuring enough slack 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. Clean the outer jacket of the cable for a distance of 24 inches (610mm). Remove the outer jacket and 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, ensuring correct dimensions for insulation and semi-con shield removal.

3. 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.

4. Prepare the Conductor

   Remove the protruding cable insulation by cutting it even with the end of the cable adapter. Exercise caution to avoid cutting or nicking the cable adapter or the conductor. Verify that the length of the exposed conductor is between 4-3/8 inches to 4-3/4 inches (111mm-121mm); if not, redo the assembly.

5. 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, ensuring it is less than 7 inches (178mm); otherwise, redo the assembly. Crimp the compression lug following the crimping 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 inches to 7-5/8 inches (175mm-194mm); if not, redo the assembly.

6. Install the Elbow Connector

   Lubricate the cable adapter and the inside of the elbow cable entrance. Install the elbow onto the cable adapter until it cannot advance further. Confirm that the cable adapter remains flush with the tape marker; if not, reposition the cable adapter. Once correctly positioned, remove the tape marker.

7. Connect to Mating Apparatus

   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. 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, ensuring surfaces remain clean. Push the elbow onto the mating part, carefully lining up the hole in the compression lug with the stud on the mating part. For the opposite end, clean and lubricate the mating part, insert it into the elbow, engage the threads, and hand tighten. Torque the mating part according to its specific instructions.

8. 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. Place the cap on the elbow and push down firmly until it snaps into place.

9. Ground the Cable Shield

   Insert one end of a piece of wire, with an 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 if no device is used. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

10. Perform Voltage Test (Optional but Recommended)

    CAUTION: When constructing 600amp L-Kits, tighten each component to specified torque per plug connector instructions. The ELASTIMOLD deadbreak elbow connector has an integral capacitance test point. To use it, remove the test point cap with a hotstick, peeling it off at an angle. 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 the specific meter used. Test with a suitable sensing device designed for capacitive test points to determine if the cable is energized. Contamination, moisture, or incorrect equipment can give a false 'no voltage' indication. Treat the elbow as energized until 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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