ABB Installation Products 756LR-L2320 35kV 600 Series Deadbreak Elbow with Test Point (with Insulated Plug, Cap, Stud, Lug and…

Frequently Asked Questions

How to Install 756/776LR Deadbreak Elbow Connectors

This guide provides step-by-step instructions for the safe installation and wiring of 756/776LR Deadbreak Elbow Connectors on 35kV class systems, ensuring fully shielded and submersible connections. Installation must be performed by competent personnel trained in high voltage electrical equipment safety practices.

Estimated time: 1h 30m

1. Ensure Safety and Inspect Components

   DANGER: De-energize all apparatus in the work area before beginning installation or removal of parts. Do not touch or move energized products. This product should only be installed by competent personnel trained in good safety practices involving high voltage electrical equipment. Inspect all parts from the 756/776LR kit for damage, correct rating, and compatibility with mating parts. Ensure all required tools and supplies are at hand and maintain cleanliness throughout the procedure.

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 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) from the cut end.

4. Prepare Cable End

   Follow the specific cable preparation instructions (refer to STEPS A, B, or C in the original document) that apply to your cable type (e.g., UNISHIELD, LEAD SHEATH, JACKETED, NON-JACKETED). This involves removing the outer jacket (if applicable) and preparing the cable insulation and semi-con shield to the specified dimensions indicated by tape markers (e.g., 10-3/8 inches, 11-3/8 inches, 13-5/8 inches).

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. Do not cut or nick the cable adapter or the conductor. The length of the exposed conductor should be between 4-3/8 inches to 4-3/4 inches (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 inches (178mm). Crimp the compression lug following the crimping instructions supplied with the lug. Wipe all excess inhibitor from the compression lug and cable adapter surface after crimping. The distance from the end of the compression lug to the cable adapter after crimping should be between 6-7/8 inches to 7-5/8 inches (175mm-194mm). If not, redo the assembly.

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

9. Prepare and Connect Mating Products

   DANGER: 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. 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. Secure Elbow to Mating Part

    Push the elbow onto the mating part, carefully lining up the hole in the compression lug with the stud on the mating part.

11. Connect Opposite End of Elbow

    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 and Cap (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 hard until it snaps into place. CAUTION: The insulating plug provides a means for detecting system voltage; follow VOLTAGE TEST directions if voltage detection is required.

13. Ground 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 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 according to the instructions supplied with the grounding device, or through an alternate method if no grounding device is used. It is also recommended that the jacket of the cable be waterproofed at this point to prevent moisture from entering the cable.

14. Tighten L-Kit Components (if applicable)

    CAUTION: When constructing 600-amp L-Kits, be sure to tighten each component to the specified torque as per the instructions provided with the plug connectors.

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