ABB Installation Products R2T15J2-T0240 Ranger2 Termination for 15KV outdoor application, cable insulation diameter .84 - 1.38…

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How to Install 15kV & 28kV Ranger 2 Cable Terminations

This guide provides detailed instructions for the safe and proper installation of 15kV and 28kV Ranger 2 Cable Terminations on concentric and jacketed concentric neutral cables for both indoor and outdoor applications. Ensure all apparatus are de-energized before starting.

Estimated time: 1h 30m

1. Perform Pre-Installation Checks

   Check the contents of the package to ensure they are complete and undamaged. Verify all components for proper fit with the cable and/or mating products. Read the entire installation instructions before starting and gather all required tools. Maintain cleanliness throughout the procedure. DANGER: All apparatus must be de-energized during installation.

2. Verify Cable Compatibility and Cut to Length

   Confirm that the cable size fits within the kit range as shown in the Termination Selection Chart. Train the cable into position and cut it to the length required for installation, allowing sufficient neutral wire length for the grounding connection.

3. Prepare Cable Insulation and Semi-Con

   Prepare the cable using the dimensions shown in the instructions. Be sure to allow for the depth of the terminal lug and provide additional exposed conductor distance to account for growth during crimping of aluminum lugs or connectors, as specified by 'X' values for different cable sizes and 'A' from Table 1.

4. Apply First Mastic Band

   Carefully wrap one band of sealing mastic around the cable jacket 1/4" (6mm) from the jacket end, using a 50% stretch. Position the mastic precisely as it also serves as a marker for positioning the terminator. Cut the mastic flush, ensuring no overlap.

5. Secure Neutral Wires

   Bend the neutral wires back over and press them into the sealing mastic. Secure the neutral wires to the cable jacket 4-6" (100-150mm) from the cut edge using vinyl tape or binding wire.

6. Apply Second Mastic Band and Tape

   Using a 50% stretch, apply a second mastic band over the neutral wires and the previously applied mastic. Cut it flush, ensuring no overlap. Then, wrap two half-lapped layers of vinyl tape around the mastic seal, carefully maintaining the 1/4" (6mm) dimension.

7. Install Terminal Lug or Connector

   If using a lug that will not fit through the termination core, clean the insulation and slide the termination onto the cable before installing the lug (do not remove the core at this time). Position the connector/lug and crimp it according to its directions, ensuring the last 1/4" to 3/8" of the connector is left uncrimped. Remove any excess oxide inhibitor and sharp crimp flashings after crimping.

8. Clean Cable Insulation and Lug Barrel

   Wipe the cable insulation with an approved solvent. Do not allow the solvent to touch the semi-con insulation shield. If abrasive cleaning is necessary, use only aluminum oxide abrasive (grit 120 or finer) on the insulation only, avoiding the semi-con insulation shield. Be careful not to reduce the cable insulation diameter below that allowed by the kit.

9. Create Track Resistant Moisture Seal at Lug Base

   Wrap a band of gray silicone rubber tape (contained in the kit) around the base of the terminal lug to create a track-resistant moisture seal. If the barrel diameter is equal to or greater than the cable primary insulation, the tape band should not exceed 2 layers. If the barrel diameter is smaller, use the tape strip to form the tape band equal to the insulation diameter.

10. Apply Silicone Grease to Semi-Con Edge

    Cover the edge of the semi-con insulation shield with a liberal coating of silicone grease. This silicone grease is used to fill the step at the semi-con cut-off.

11. Prepare Termination for Sliding

    If installing a lower termination with a fold-down skirt, pull the loose end of the removable core through the top of the termination until the core is flush with the bottom of the termination.

12. Slide Termination Body and Remove Core

    Slide the termination body onto the cable, aligning the terminator with the forward edge of the mastic seal (under the vinyl tape). Carefully begin to remove the core by unwinding it counter-clockwise, starting with the loose end. Make sure the termination body, not the core, is butted up to the leading edge of the mastic seal. Do not push or pull on the termination assembly while removing the core material.

13. Lubricate and Fold Down Skirt

    Apply a thin film of silicone lubricant to the skirt and mastic seal area. Do not lubricate the skirt tabs. Carefully fold down the skirt over the mastic seal.

14. Complete Lug Area Moisture Seal

    With the termination installed, complete the lug area moisture seal using the remaining gray silicone rubber tape. Overlap the termination insulator by approximately 1" and extend the tape wrapping over a non-crimped region of the lug/connector barrel with a half-lap configuration.

15. Connect Neutral Wires to Ground

    Twist the concentric neutral wires together and connect them to the system ground.

16. Confirm High-K Step

    Confirm that the High-K step does not exceed 1.5".

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