ELB-35-600

ELB-35-610
600A T-Body Elbow Connectors for Copper Tape
(CT), Jacketed Concentric Neutral (JCN), and
Concentric Neutral (CN) cables up to 35kV class

Copper Tape application

If using Copper Tape cables, Tyco Electronics Grounding Conductive
cap Elbow
Kit (part number 6L7961-000) or equivalent will be
required.

Kit Contents Stud

Insulating
1 Conductive cap plug
1 Insulating plug
1 Stud
1 Elbow
1 Compression lug (with crimp chart)
1 Cable adapter Optional
5 Silicone lubricant test point
1 Installation instruction

Suggested Installation Equipment (not supplied with kit)

• Cable preparation tools
• Clean, lint-free cloths
• Non-conducting abrasive cloth, 120 grit or finer Compression lug
• Connector(s) and installation tools

Safety Instructions
DANGER: When installing electrical power system Cable adapter
accessories, failure to follow applicable personal safety
requirements and written installation instructions could
result in fire or explosion and serious or fatal injuries.

As Tyco Electronics has no control over field conditions Fig. 101

which influence product installation, it is understood

that the user must take this into account and apply his
own experience and expertise when installing product.
All apparatus must be de-energized during installation
or removal of parts.
Customer Service
For 24 hour customer service, call 800-327-6996.
General Information
The Tyco Electronics ELB-35-600 and ELB-35-610
35kV class 600A elbows are used to terminate high-
voltage cable on deadfront apparatus transformers
and switchgear or make separable splice or junction
connections. They are fully shielded, fully submersible
and are interchangeable with all other manufacturers
that certify compliance with IEEE standard 386.

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Installation Instructions
1. Check kit

Check kit components to insure proper fit with the

cable diameter dimensions, conductor size, and mating
products.

2. Cut cable

Position the cable so that it is parallel to the apparatus CL Bushing

faceplate and is located in the final assembled position 1-3/4” (45mm)
with enough slack to allow movement of elbow to Cut
insulated parking bushing. Cut cable 1-3/4“ (45mm)
from the centerline of the mating bushing. If using a

Cable
Transformer
jacket sealing device park it on the cable now. Follow
instructions in the jacket sealing kit after elbow
assembly is complete. Park jacket
sealing device

Fig. 102

Choose the cable type (Choice 1 or 2) and follow the

directions given.

Choice 1: Jacket Concentric Neutral or

Concentric Neutral cable

3. Prepare cable

If jacketed neutral cable, remove outer jacket 13” 13” (330mm)

(330mm) from end of cable. If unjacketed neutral
cable, bind neutral wires using red marking tape at Concentric 2-1/2" 10-1/2"
15”(380mm). Fold back neutral wires allowing enough neutral wires (67mm) (267mm)
extra length to connect to ground and allow elbow
movement to insulated parking bushing. Remove semi-
con insulation shield 10-1/2” (267mm) from the end of
Extruded semi-con 1" (25mm) Cable
the cable with a straight, smooth, squared cut. Do not insulation shield insulation
cut or nick the insulation. Wrap two turns of marking
tape 1” (25mm) from end of semi-con shield. This will Marking tape
be a guide for the cable adapter location. Fig. 103

4. Remove insulation 4-3/8” - 4-5/8”

(111mm-118mm)
Remove insulation exposing conductor between 4-3/8”
and 4-5/8”.

When completed, go to step 9 on page 4. Marking tape Cable Bare Fig. 104
insulation conductor

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 Choice 2: Copper Tape cable

5. Prepare cable 14-1/4” (362mm)

Note: If using Copper Tape cables, Tyco Electronics 3-1/2" 10-1/2"

Copper (87mm)
Grounding Kit (part number 6L7961-000) or equivalent (263mm)
tape shield
will be required.

Remove outer jacket 14-1/4” (362mm) from end of Extruded semi-con 1" (25mm) Cable
cable. Remove semi-con insulation shield 10-1/2” insulation shield insulation
(267mm) from the end of the cable with a straight,
Marking tape Fig. 103
smooth, squared cut. Do not cut or nick the insulation.
Wrap two turns of marking tape 1” (25mm) from end
of semi-con shield. This will be a guide for the cable
adapter location.

6. Install ground braid

(1) Lay the ground braid on the cable with the solder Ground Moisture
block aligned with the jacket cutback and the short end braid block Spring clamp
of the braid over the exposed copper tape shield.

(2) Attach the braid to the tape shield by placing two

wraps of the spring clamp over the braid.

(3) Fold the short end of the braid back over the spring
clamp wraps as shown. Continue to wrap the remaining 1 2 3
clamp over the braid. Tighten clamp by twisting it in the
Fig. 519
direction it is wrapped and secure with the copper foil
tape provided.

7. Park black tube 6" (152mm)

Insert black tube over cable jacket and park it 6” from

cable jacket cutback.
Fig. 524
Black, adhesive lined tube

Temporarily secure black tube to cable jacket with

insulating tape.
Insulating tape Fig. 525

8. Remove insulation 4-3/8” - 4-5/8”

(111mm-118mm)
Remove insulation exposing conductor between 4-3/8”
and 4-5/8”.
Fig. 104
When completed, go to step 9 on page 4. Marking tape Cable Bare
insulation conductor

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9. Chamfer and clean insulation 1/4”
45 0 (6mm)
Remove sharp edge of insulation by chamfering the end
of the cable insulation at a 450 angle, approximately
1/4” back. Thoroughly clean the insulation with a Clean
Chamfer
solvent dampened cloth, wiping from conductor
toward cable semi-con shield. Ensure that all traces of
conductive residue are removed. Marking tape Cable Fig. 105
insulation

10. Lubricate and install cable adapter

Lubricate Lubricate
Lubricate exposed cable insulation with silicone grease inside
always working toward cable semi-con shield. Lubricate
inside of cable adapter. Install cable adapter, small end
first, over cable using a twisting motion until it is flush Marking tape Cable Cable
with the edge of the tape marker. insulation adapter
Fig. 106

11. Ensure position of cable adapter

The cable adapter has a step molded into the cable Slide
Marking tape
entrance.
Cable
When sliding the cable adapter on you should feel a adapter
positive stop when the step in the adapter meets the
step in the semicon of the cable. The positive stop
should be felt at the same location as the tape mark.
Semicon Adapter step
D0 NOT slide adapter past this step. If you suspect you
step
have slid the adapter past the step, pull adapter off and
repeat step 7. When you are certain that the cable is in
the correct position, secure cable adapter in position by PVC tape
wrapping five half lapped layers of PVC tape over the Cable
small end of the cable adapter and over the marking adapter
Fig. 107
tape.

12. Install compression connector

Copper conductor: Remove protective cap and fully 1/2" (13mm)

insert conductor into compression lug.
Aluminum conductor: Prepare aluminum conductor Lug
Parallel
by wire brushing just prior to insertion into connector. Place first crimp here flats
Remove protective cap and fully insert conductor into
Bushing

compression lug.

Connector must be fully seated on cable conductor.

Align flats of lug and bushing before crimping. Start
crimps at the lug end 1/2” (13mm) below shoulder of
compression connector and work down. Crimp the Transformer
compression lug following the crimping instruction
supplied with the lug. Wipe all excess inhibitor from
connector and cable adapter surfaces. Fig. 108

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13. Check dimension Check dimension
after crimping
The distance from the end of the lug to the cable adapter
after crimping should be between 6-1/2” to 7-1/2”
(165mm – 190mm). Otherwise redo assembly.
6-1/2” to 7-1/2”
(165 -190mm)
Fig. 109

14. Install elbow on cable

Clean and evenly lubricate the entire surface of cable Optional test
adapter with silicone grease. Lubricate inside the cable point facing
entrance of the elbow wiping 360º around the entire installer
surface and at least 2” (50mm) deep. If test point elbow
is used, ensure that test point is facing towards installer.
Push elbow onto cable adapter until lug eye is centered
in the 600A interface. You must ensure that the cable
2” Elbow
adapter does not move while installing the elbow.
Clean and Clean and
Lubricate Lubricate
inside surface
2” (50mm)
Fig. 110

Note: If using Jacketed Concentric Neutral or

Concentric Neutral cable, go to step 21 on page 7,
or follow the directions given below for Copper Tape
cable.

15. Prepare cable and install elbow 2” (52mm) maximum

Prepare rest of cable and install elbow per

manufacturer’s instructions.

Make sure the gap between the cable jacket cutback

and the end of the elbow does not exceed 2” (50mm)..
Fig. 1025

16. Clean cable and apply red sealant Clean

Clean from the elbow grounding eye to the cable jacket

cutback using an approved solvent capable of removing
silicone grease. Make sure all grease is removed from
elbow’s bottom and before wrapping mastic.

Fig. 1026

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17. Complete ground braid and ground cable sealing Clean

Lift ground braid away from the cable jacket. Using

an oil-free solvent, clean the jacket for 2-1/2” (60mm)
below the jacket cutback point.

Fig. 524a

Remove the backing from the red sealant. Using light

tension, wrap two layers of red sealant onto the jacket 2 Layers
red sealant
under the braid.

Fig. 525a

Lay the braid back over the jacket and through the black
tube. Press moisture blocked section of braid into the 2 Layers
red sealant. Using light tension wrap two more layers of red sealant
red sealant over the braid.

Fig. 526a

18. Apply red sealant 1 Layer

red sealant
Wrap one complete layer of sealant centered half on
elbow and half on semi-con.

Elbow
Red sealant Fig. 1026b

19. Position black tube; shrink in place per

manufacture’s instructions

Remove insulating tape. Position black tube to overlap

sealant applied to cable jacket and elbow.

Shrink in place beginning at the elbow end of the tube

and work toward the cable jacket end. Apply the torch Torch
with a smooth, brushing motion around all sides of the
tube.

When shrinking is complete, the outline of underlaying

parts should be visible.

Allow time to cool before touching then proceed to Step 20.

Fig. 1027a

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20. Connect copper wire

Note: Solid copper wire and connector not included in

kit.

Fig. 1027b

Attach solid copper wire (10-14 AWG) to copper braid Connector

by crimping or bolted connector. Connect wire to either
grounding tab on the elbow’s lower body area.

Solid copper wire (10-14 AWG)

Fig. 1027c

21. Assemble elbow on bushing

Clean and lubricate the entire mating surfaces of

bushing and elbow interfaces. Push elbow onto Bushing

apparatus bushing.
Transformer
Clean
and lubricate
mating
surfaces

Fig. 111

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22. Prepare insulating plug Insulating
plug
Stud
Hand tighten the threaded stud into the insulating plug
or mating part. Clean and lubricate the mating surfaces
of insulating plug and elbow interface.
Transformer

Clean
and lubricate
mating
surfaces

Fig. 112

23. Install insulating plug Apply torque

55ft-lbs
Push plug into the elbow and tighten to apparatus
bushing using a torque wrench and 1” socket. Tighten
plug clock-wise exerting 55 ft-lbs (75 N-m) of torque. Transformer
The insulating plug provides a capacitive test point for
detecting system voltage. The ELB-35-610 elbow has
ELB-35-610
an integral capacitive test point on the body. Follow
optional test point
VOLTAGE TEST directions on page 7.

Fig. 113

24. Install conductive cap Conductive

cap
Clean and lubricate inner surface of conductive cap with
lubricant supplied. Push cap onto insulating plug until it
snaps into place.
Clean Transformer
and lubricate
inside
surface

Fig. 114

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25. Ground system

Jacket Concentric Neutral or Concentric Neutral

cable:
Connect grounding eye of elbow with a minimum #14
AWG copper drain wire to cable concentric neutral
wires or to common ground point.
Transformer

#14 AWG
drain wire

Fig. 115

Copper Tape cable:

Ground to common ground point.

Transformer

Ground
copper braid

Fig. 115

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Capacitive Voltage Test

The Tyco Electronics ELB-35-610 elbow is provided

with an integral capacitive test point on the body. Both
the ELB-35-600 and ELB-35-610 elbows kits contain an
insulating plug that has a test point as noted in step 13.
Complete the following steps to use the test point:
Test
• Remove test point cap with a hotstick. Rather than point
pulling directly in line with the test point assembly.
PEEL OFF AT AN ANGLE.

• Using a suitable sensing device, determine if the cable

is energized. WARNING: Use only voltage indicating
instruments specifically designed for capacitive test Test
point
points. Use of conventional voltage sensing devices
may provide a false “No Voltage” indication. The test
point must be dry and free of contaminants when
checking for voltage. To prevent serious or fatal injury
treat the elbow as energized until the “No Voltage” test
point indication is confirmed by other means.

• After voltage detection has been made, clean and

lubricate the inside surface of the test point cap with
silicone grease and replace it on the test point with a
hot stick.
Fig. 116

The Information contained in these installation instructions is for use only by installers trained to make electrical power installations and is intended to describe the correct method
of installation for this product. However, Tyco Electronics Corporation has no control over the field conditions which influence product installation. It is the user’s responsibility to
determine the suitability of the installation method in the user’s field conditions. Tyco Electronics’ only obligations are those in Tyco Electronics’ standard Conditions of Sale for this
product and in no case will Tyco Electronics be liable for any other incidental, indirect or consequential damages arising from the use or misuse of the products.

TE (logo) and Tyco Electronics are trademarks. Copyright 2009 Tyco Electronics Corporation. All Rights Reserved.

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