ABB Installation Products 756LR-Q0440-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 756LR and 776LR Deadbreak Elbow Connectors on 35kV class systems, ensuring fully shielded and submersible cable connections.

Estimated time: 1h 30m

1. Perform Pre-Installation Safety Checks

   DANGER: All apparatus must be de-energized during installation or removal of parts. Do not touch or move energized products in the work area. This product should be installed only by competent personnel trained in good safety practices involving high voltage electrical equipment. Inspect all parts for damage, proper rating, and compatibility with mating parts. Ensure all package contents are complete and undamaged, and verify proper fit with cable and/or mating products. Read all instructions thoroughly before beginning.

2. Position and Clean the Cable

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

3. Prepare the Cable

   Follow the specific cable preparation instructions for your cable type (e.g., UNISHIELD, Lead Sheath, Jacketed, Non-Jacketed). Remove the outer jacket (where applicable) and prepare the cable insulation, semi-con shield, and shield wires/tape to the dimensions specified in the provided diagrams. If using a grounding device or cable seal, refer to their specific instructions.

4. Install the 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.

5. Prepare the Conductor

   Carefully remove the protruding cable insulation by cutting it even with the end of the cable adapter. Ensure you do not cut or nick the cable adapter or the conductor. Verify that the length of the exposed conductor is between 4-3/8 inches to 4-3/4 inches (111mm-121mm). If not, redo the assembly.

6. Install and 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. Verify the distance from the end of the compression lug to the cable adapter after crimping is between 6-7/8 inches to 7-5/8 inches (175mm-194mm). If not, redo the assembly.

7. 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.

8. Prepare 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. 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 all surfaces clean.

9. Connect Elbow to Mating Part

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

10. Connect Opposite Mating Part (if applicable)

    If connecting an opposite mating part, clean and lubricate it. Insert the 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.

11. 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. Place the cap on the elbow and push down firmly until it snaps into place. CAUTION: The insulating plug provides a means for detecting system voltage; follow voltage test directions carefully.

12. 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 cable shield must be grounded; follow instructions supplied with any grounding device or use an alternate method. It is also recommended to waterproof the cable jacket at this point to prevent moisture ingress.

13. Perform Voltage Test

    CAUTION: When constructing 600amp L-Kits, tighten each component to specified torque per plug connector instructions. To test for voltage, remove the test point cap with a hotstick, peeling it off at an angle. WARNING: The voltage test point is a capacitance device, not directly connected to the conductor. Do not use conventional voltage measuring equipment. Use a suitable sensing device designed for capacitive test points and follow its manufacturer’s directions. Contamination or incorrect equipment can give a false 'no voltage' indication. Treat the elbow as energized until the 'no voltage' indication is confirmed by other means to prevent serious injury. 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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