ABB Installation Products 756LR-P0410 35kV 600 Series Deadbreak Elbow with Test Point (with Insulated Plug, Cap, Stud, Lug and…

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How to Install 756LR/776LR Deadbreak Elbow Connectors

This guide provides detailed instructions for the safe installation and setup of 756LR and 776LR Deadbreak Elbow Connectors on 35kV class systems, ensuring fully shielded and submersible cable connections. All apparatus must be de-energized during installation or removal of parts. This product should only be installed by competent personnel trained in high voltage electrical equipment safety practices.

Estimated time: 2h

1. Prepare for Installation and Inspect Components

   De-energize all apparatus in the work area. Inspect all parts for damage, proper rating, and compatibility with mating parts. Check the contents of the package to ensure completeness. Confirm all components fit properly with the cable and/or mating products. Have all required tools at hand and maintain cleanliness throughout the procedure.

2. Prepare the Cable

   Position the cable in its final assembled location, ensuring enough slack for elbow removal. Cut the cable 1-3/4 inches (45mm) from the centerline of the mating product. Clean the outer jacket of the cable for a distance of 24 inches (610mm). Follow specific instructions for 20MA/21MA grounding devices, 600ECS Jacket Cable Seals, UNISHIELD*, or LEAD SHEATH cables. For jacketed and non-jacketed cables, remove the outer jacket (if applicable) and prepare the cable according to the provided diagrams, ensuring correct lengths for insulation, semi-con shield, and neutral wires.

3. Install the Cable Adapter and Prepare Conductor

   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. Remove the protruding cable insulation by cutting it even with the end of the cable adapter, taking care not to cut or nick the cable adapter or conductor. The exposed conductor length must be between 4-3/8 inches to 4-3/4 inches (111mm-121mm); redo assembly if outside this range.

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 into the compression lug. Measure the 'Check Dimension' before crimping; it should be less than 7 inches (178mm). Crimp the compression lug according to the 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 must be between 6-7/8 inches to 7-5/8 inches (175mm-194mm); redo assembly if outside this range.

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 the cable adapter if necessary. Remove the tape marker.

6. Connect to the Mating Product

   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 is not already equipped with a stud. Clean and lubricate both the elbow and the mating part with the supplied lubricant, keeping surfaces clean. Push the elbow onto the mating part, carefully aligning the hole in the compression lug with the stud on the mating part.

7. Secure the Opposite End (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.

8. Install the 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 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 carefully.

9. Ground the Cable Shield and Waterproof

   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 according to the instructions supplied with the grounding device; if no grounding device is used, ground the shield through an alternate method. It is also recommended to waterproof the cable jacket at this point to prevent moisture from entering the cable.

10. Perform Post-Installation Voltage Test

    CAUTION: When constructing 600-amp L-Kits, ensure each component is tightened to the specified torque per instructions provided with plug connectors. To test for voltage, 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 and is not directly connected to the conductor. Do not use conventional voltage measuring equipment. Use a suitable sensing device designed for separable connectors with capacitive test points to determine if the cable is energized. Contamination, moisture, dirt, or incorrect equipment can cause a false 'no voltage' indication. Treat the elbow as energized until the 'no voltage' test point indication is 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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