ABB Installation Products 775LR-K2260 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 (600-ampere) and 775LR (900-ampere) deadbreak elbow connectors on 35kV class systems, including cable preparation, lug crimping, and connection to mating apparatus.

Estimated time: 2h

1. De-energize Apparatus and Inspect Parts

   DANGER: De-energize all apparatus in the work area before beginning installation or removal of any parts. Do not touch or move energized products. Inspect all parts for damage, proper rating, and compatibility with mating components. Ensure all required tools and supplies are at hand and maintain cleanliness throughout the procedure.

2. Position Cable and Clean Outer Jacket

   Position the cable in its final assembled location, ensuring enough slack for elbow removal. If using concentric neutral cable, unwind the neutral wires. Cut the cable 1-3/4” (45mm) from the centerline of the mating product. Clean the outer jacket of the cable for a distance of 24” (610mm).

3. Prepare Cable According to Type

   Prepare the cable by removing the outer jacket (if applicable) and other layers as specified for your cable type (e.g., non-jacketed concentric neutral, jacketed shield wires, flat metallic tape shield, fabric tape shield, or longitudinally corrugated shield). Refer to the provided diagrams for precise measurements of cable insulation, semi-con shield, and tape marker placement. If using a 20MA/21MA grounding device, 600ECS Jacket Cable Seal, or 10TL cable shield adapter, follow their specific installation instructions for cable preparation.

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 towards 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

   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. The exposed conductor length must be between 4-3/8” to 4-3/4” (111mm-121mm). If the length is outside this range, redo the assembly.

6. 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 following the instructions supplied with the lug. After crimping, wipe all excess inhibitor from the 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). If dimensions are incorrect, redo the assembly.

7. Install Elbow onto Cable Adapter

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

8. Prepare Mating Products

   WARNING: Do not connect or disconnect mating products while energized. Do not energize while disconnected. Remove any protective caps from both the elbow and the mating part. Hand tighten the threaded stud (supplied with the elbow) into the mating part if it 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.

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. Ensure a firm and secure connection.

10. Connect Opposite End of Elbow (if applicable)

    Clean and lubricate the mating part intended 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 specific instructions provided with that mating part.

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 onto the elbow and push down firmly until it snaps securely into place.

12. Ground the Cable Shield

    Insert one end of a grounding wire (with ampacity at least equivalent to No. 14 AWG Copper) through the grounding eye and twist it 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 your 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

    CAUTION: For 600amp L-Kits, tighten each component to the specified torque per plug connector instructions. Remove the test point cap using a hotstick, peeling it off at an angle rather than pulling directly. 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. Contamination, moisture, dirt, or incorrect equipment can provide a false 'no voltage' indication. Treat the elbow as energized until the 'no voltage' indication is confirmed by other means to prevent serious or fatal 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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