ABB Installation Products R2T15M1-N0270 Ranger2 Termination for 15KV outdoor application, cable insulation diameter 0.64 - 1.12…

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How to Install the R2T15M1 Silicone Rubber Termination for Tape Shielded Cables

This guide provides step-by-step instructions for the safe and proper installation of the R2T15M1 Ranger 2 Shrink-fit Silicone Rubber Termination on tape shielded cables, including cable preparation, ground braid installation, and termination placement.

Estimated time: 2h

1. Safety First: De-energize Apparatus and Inspect Components

   De-energize all apparatus in the work area before beginning installation. Do not touch or move energized products. Inspect all kit contents for completeness and damage. Verify all components are compatible with the cable and mating parts. Read the entire installation instructions thoroughly before starting.

2. Prepare the Cable for Termination

   Confirm the cable size is within the insulation range specified in the Termination Selection Chart. Train the cable into its final position and cut it to the required length, allowing for terminal lug depth and growth allowance. Remove the cable jacket to the length specified as 'A' in Table 1, plus 2 inches (50mm) for terminal lug depth and growth allowance. Remove the tape shield 1 inch (25mm) from the jacket end. Secure the edge of the tape shield with a single wrap of the supplied copper foil tape to prevent unrolling. Provide additional exposed conductor distance for aluminum lugs: 1/4 inch (6mm) for 2/0-350 Kcmil, 1/2 inch (13mm) for 400-650 Kcmil, and 3/4 inch (19mm) for 750-1000 Kcmil.

3. Install the Ground Braid Assembly

   Wrap one band of sealing mastic around the cable jacket, 1/4 inch (6mm) from the jacket end, using 50% stretch. Cut the mastic flush without overlapping. This band also serves as a termination positioning marker. Position the preformed ground braid with its short tail over the tape shield and the solder block centered over the mastic strip. Secure the ground braid to the cable jacket using vinyl tape and press the solder block firmly into the mastic. Apply a second band of mastic over the solder block and the first mastic band, maintaining the 1/4 inch (6mm) dimension, using 50% stretch. Cut flush. Wrap two half-lapped layers of vinyl tape around the mastic seal, carefully maintaining the 1/4 inch (6mm) dimension. Wrap the ground braid around the cable tape shield for one complete wrap, trim any excess to prevent overlap, and secure it in place with the constant force spring. Wrap the spring in the same direction as the ground braid. Cinch (tighten) the constant force spring after wrapping the final winding and secure it with two wraps of vinyl tape.

4. Install the Terminal Lug or Connector

   Before crimping, check that the termination assembly (with its core intact) can slide over the selected lug. If it cannot, clean the cable insulation and slide the termination onto the cable before installing the lug. Position the connector or lug and crimp it according to the manufacturer's instructions. Avoid crimping the last 3/8 to 1/2 inch (10-13mm) of the connector. Remove any excess oxide inhibitor and all sharp crimp flashings or edges after crimping.

5. Clean Cable Insulation and Prepare for Termination

   Wipe the cable insulation thoroughly with an approved solvent using saturated pads. Ensure the solvent does not touch the semi-conductive insulation shield. If abrasive cleaning is necessary, use only aluminum oxide abrasive (grit 120 or finer) on the insulation, not the semi-conductive shield. Exercise caution to avoid reducing the cable insulation diameter below the kit's specified allowance. Create a track-resistant moisture seal by wrapping a band of gray silicone rubber electrical tape around the base of the terminal lug. If the lug barrel diameter is equal to or greater than the cable primary insulation, use no more than two layers. If smaller, build up the tape band to match the insulation diameter. Apply a liberal coating of silicone grease to the edge of the semi-conductive insulation shield to fill the step at the cut-off point.

6. Install the Silicone Rubber Termination Body

   For lower terminations 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. Slide the termination body onto the cable. Align the termination 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. Ensure the termination body, not the core, is butted up to the leading edge of the mastic seal. Continue removing the core completely. Do not push or pull on the termination assembly while removing the core.

7. Complete the Termination Sealing and Grounding

   Apply a thin film of silicone lubricant to the skirt and mastic seal area, but do not lubricate the skirt tabs. Carefully fold down the skirt over the mastic seal. Complete the lug area moisture seal using the remaining gray silicone rubber electrical tape. Overlap the termination insulator by approximately 1 inch (25mm) and extend the tape wrapping over a non-crimped region of the lug/connector barrel using a half-lap configuration. Connect the ground braid securely to the system ground. Confirm that the High-K step of the termination does not exceed 1.5 inches (38mm) over the cable semi-conductive shield.

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