ABB Installation Products 756LR-J0250 35kV 600 Series 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 installation of 756/776LR Deadbreak Elbow Connectors, designed for fully shielded, submersible cable connections on 35kV class systems.

Estimated time: 2h

1. Prepare for Installation and Ensure Safety

   De-energize all apparatus in the work area. Inspect all parts (elbow, cable adapter, lug, etc.) for damage, correct rating, and compatibility with mating parts. Verify the package contents are complete and undamaged. Ensure all components fit properly with the cable and/or mating products. Gather all required tools and supplies, and maintain cleanliness throughout the procedure. Safety Warning: This product must be installed only by competent personnel trained in high voltage electrical safety practices.

2. Prepare the Cable

   Position the cable in its final assembled location, ensuring enough slack for elbow removal. 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). Prepare the cable by removing the outer jacket, semi-con shield, and exposing the cable insulation according to the specific cable type (e.g., non-jacketed concentric neutral, jacketed shield wires, etc.) and the provided dimensions (e.g., 10-3/8”, 11-3/8”, 13-5/8” tape markers). Refer to specific instructions for UNISHIELD, LEAD SHEATH, or if using grounding devices/cable seals.

3. Install Cable Adapter and Prepare Conductor

   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, working towards the semi-con shield. Install the cable adapter, small end first, until it is flush with the edge of the tape marker. Remove the protruding cable insulation by cutting it even with the end of the cable adapter, ensuring not to cut or nick the adapter or conductor. The exposed conductor length must be between 4-3/8” to 4-3/4” (111mm-121mm).

4. 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. Measure the 'Check Dimension' before crimping; it must be less than 7” (178mm). Crimp the compression lug following the instructions supplied with the lug, ensuring the first crimp is located on the specified end. Wipe all excess inhibitor from the compression lug and cable adapter surface after crimping. Verify the distance from the end of the compression lug to the cable adapter is between 6-7/8” to 7-5/8” (175mm-194mm) after crimping.

5. Install the 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.

6. Connect to Mating Apparatus

   Safety Warning: Do not connect or disconnect mating products while energized. Do not energize while disconnected. Remove any protective caps from 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, keeping surfaces clean. Push the elbow onto the mating part, aligning the hole in the compression lug with the stud on the mating part.

7. Connect Second Mating Part and Ground Cable Shield

   If connecting a second mating part to the opposite end of the elbow, clean and lubricate it. Insert it into the elbow, engage the threads, hand tighten, and then torque it according to its specific instructions. Insert one end of a No. 14 AWG Copper wire (or equivalent) through the grounding eye and twist to form a small loop without damaging the eye. Connect this wire to ground using a suitable connector. Ground the cable shield according to the instructions supplied with the grounding device, or by an alternate method if no device is used. Waterproof the cable jacket at this point to prevent moisture ingress.

8. Perform Voltage Test and Finalize

   If an insulating plug is used as a mating part, clean and lubricate the inner surface of its voltage detection cap and push it onto the elbow until it snaps into place. To test for voltage, remove the test point cap with a hotstick, peeling it off at an angle. Safety Warning: The voltage test point is a capacitance device; do not use conventional voltage measuring equipment. Use a suitable capacitive sensing device and follow its manufacturer’s directions. Treat the elbow as energized until a 'no voltage' indication is confirmed by other means. After voltage detection, clean and lubricate the inside surface of the test point cap with silicone lubricant and replace it. Caution: If constructing 600amp L-Kits, ensure all components are tightened to specified torque per plug connector instructions.

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