ABB Installation Products 756LR-H0240 600 Amp, 35KV, DeadBreak, Elbow with Test Point, with Insulated Plug, Cap, Stud, Lug and…

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How to Install 756/776LR Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe and proper installation of 756LR and 776LR Deadbreak Elbow Connectors, designed for fully shielded, submersible high-voltage cable connections on 35kV class systems.

Estimated time: 2h

1. De-energize Apparatus and Inspect Parts

   DANGER: All apparatus must be de-energized during installation or removal of parts. Do not touch or move energized products. Inspect all parts for damage, proper rating, and compatibility with mating parts. Remove any protective shipping covers and replace them with appropriate HV insulated caps or connectors before submerging or energizing the circuit. Check package contents for completeness and ensure all components fit properly with the cable and/or mating products.

2. Position and Cut Cable

   Position the cable in its final assembled location, ensuring enough slack to provide adequate clearance for removing the elbows. Cut the cable 1-3/4” (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” (610mm).

4. Prepare Cable for Connection

   Refer to the specific installation instructions supplied with 20MA or 21MA grounding devices, 600ECS Jacket Cable Seals, UNISHIELD*, or LEAD SHEATH cables for their respective cable preparation. For jacketed and non-jacketed cables, remove the outer jacket (where applicable) and prepare the cable according to the provided diagrams, ensuring correct dimensions for cable insulation, semi-con shield, and tape markers.

5. 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.

6. Prepare Conductor Length

   Remove the protruding cable insulation by cutting it even with the end of the cable adapter. Do not cut or nick the cable adapter or the conductor. The length of the exposed conductor must be between 4-3/8” to 4-3/4” (111mm-121mm). If the length is outside this range, 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; this dimension should be less than 7” (178mm). 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 after crimping should be between 6-7/8” to 7-5/8” (175mm-194mm). If the dimension is outside this range, redo the assembly.

8. 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 the elbow cannot advance further. Ensure the cable adapter is still flush with the tape marker. If not, reposition the cable adapter. Remove the tape marker.

9. Prepare Mating Products

   DANGER: DO NOT CONNECT OR DISCONNECT MATING PRODUCTS WHILE ENERGIZED. DO NOT ENERGIZE WHILE DISCONNECTED. Remove protective caps from 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.

10. Connect Elbow to Mating Part

    Push the elbow onto the mating part, 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 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 and place it on the elbow. Push down hard until the cap snaps into place. CAUTION: The insulating plug provides a means for detecting system voltage; follow the voltage test directions below.

13. Ground 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 make a small loop, taking care not to damage the eye. Connect this wire to ground using a suitable connector. The shield of the cable must be grounded; ground it according to the instructions supplied with the grounding device. If no grounding device is used, the shield must be grounded through an alternate method. It is also recommended that the jacket of the cable be waterproofed at this point to prevent moisture from entering the cable.

14. Perform Voltage Test (if applicable)

    CAUTION: When constructing 600amp L-Kits, ensure each component is tightened to the specified torque per the instructions provided with the plug connectors. If the ELASTIMOLD® connector is equipped with an integral capacitance test point, remove the test point cap with a hotstick, peeling it off at an angle rather than pulling directly in line. 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, made for use with separable connectors manufactured with capacitive test points, to determine if the cable is energized. Contamination, moisture, dirt, or using the wrong measuring equipment can provide a false “no voltage” indication on an energized elbow. To prevent serious or fatal injury, treat the elbow as energized until the “no voltage” test point indication is confirmed by other means. After voltage detection, clean and lubricate the inside surface of the cap with silicone lubricant and replace it on the test point.

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