ABB Installation Products 756LR-N0380-S 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 and proper installation of 756/776LR Deadbreak Elbow Connectors, designed for 35kV class systems to create fully shielded, submersible cable connections.

Estimated time: 2h

1. Ensure Safety and Prepare for Installation

   DANGER: All apparatus must be de-energized during installation or removal. Do not touch or move energized products. This product should only be installed by competent personnel trained in high voltage electrical equipment safety. Inspect all parts for damage, rating, and compatibility. Check package contents for completeness and ensure proper fit with cable and mating products. Have all required tools at hand and maintain cleanliness throughout the procedure.

2. Position and Cut Cable

   Position the cable in its final assembled location, ensuring enough slack for adequate clearance to remove 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 Connector

   Prepare the cable according to its specific type (e.g., UNISHIELD, LEAD SHEATH, Jacketed, or Non-Jacketed). Refer to the installation instructions supplied with any 20MA/21MA grounding device, 600ECS Jacket Cable Seal, or 10TL cable shield adapter if these products are being used. Remove the outer jacket (where applicable) and prepare the cable to the specified dimensions for insulation, semi-con shield, and tape markers as detailed in the product diagrams.

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 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. Verify that the length of the exposed conductor is 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. 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 after crimping is between 6-7/8” to 7-5/8” (175mm-194mm); otherwise, 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 and Connect 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. 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. CAUTION: When constructing 600amp L-Kits, tighten each component to the specified torque per instructions provided with plug connectors.

12. Install Insulating Plug (if applicable)

    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. This insulating plug provides a means for detecting system voltage.

13. Ground the Cable Shield

    Insert one end of a piece of 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; follow the instructions supplied with any 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)

    If the ELASTIMOLD® connector is equipped with an integral capacitance test point, remove the test point cap with a hotstick by peeling it off at an angle, rather than pulling directly. 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, which must be a suitable sensing device made for use with separable connectors manufactured with capacitive test points. Contamination, moisture, or incorrect equipment can provide a false 'no voltage' indication. Treat the elbow as energized until the 'no voltage' test point indication is confirmed by other means to prevent serious or fatal injury. 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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