ABB Installation Products 776LR-L5270-S 900 Amp, 35kV, 600 Series Elbow with Test Point, with Insulated Plug, Cap, Stud, Lug and…

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How to Install 755/775LR Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe installation and connection of 755LR and 775LR Deadbreak Elbow Connectors on 35kV class systems, including cable preparation and grounding procedures.

Estimated time: 1h 30m

1. Perform Initial Safety Checks and Inspection

   DANGER: Ensure all apparatus is de-energized during installation or removal. Do not touch or move energized products. This product must be installed only by competent personnel trained in high voltage electrical equipment safety practices. Inspect all parts for damage, proper rating, and compatibility with mating parts. Check package contents for completeness. Read all instructions before starting and have all required tools at hand. If supplied with protective shipping covers, remove them and replace with appropriate HV insulated caps or connectors before submerging or energizing the circuit.

2. Position and Cut Cable

   Position the cable in its final assembled location, 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.

3. Clean Cable Outer Jacket

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

4. Prepare Cable

   Prepare the cable according to its specific type (e.g., Non-Jacketed Concentric Neutral, Jacketed Shield Wires, etc.) and the provided diagrams. Remove the outer jacket (where applicable) and semi-con shield as specified. If using a grounding device or cable seal, refer to their specific instructions for cable jacket removal and shield connection.

5. Install 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. Prepare Conductor and Verify Length

   Remove the protruding cable insulation by cutting it even with the end of the cable adapter. Exercise caution not to cut or nick 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.

7. Crimp Compression Lug

   For copper conductors, fully insert the conductor into the compression lug. For aluminum conductors, wire brush the conductor and immediately fully insert it into the compression lug. Measure the 'Check Dimension' before crimping; it must be less than 7 inches (178mm). Crimp the compression lug following the instructions supplied with the lug. Wipe all excess inhibitor from the lug and cable adapter surface after crimping. Verify the distance from the end of the compression lug to the cable adapter after crimping is between 6-7/8 inches to 7-5/8 inches (175mm-194mm). If not, redo the assembly.

8. Install Elbow

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

9. Prepare Mating Products for Connection

   WARNING: DO NOT CONNECT OR DISCONNECT MATING PRODUCTS WHILE ENERGIZED. 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 does not have one. 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 Mating Part (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 onto the elbow and push down firmly until it snaps securely 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

    CAUTION: For 600amp L-Kits, ensure each component is tightened to the specified torque per plug connector instructions. Remove the test point cap with 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. 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 or incorrect equipment can cause a false 'no voltage' indication; treat the elbow as energized until confirmed by other means. 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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