ABB Installation Products R2T28J2-T0230 Ranger2 Termination for 25/28KV outdoor application, cable insulation diameter .84…

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How to Install the 28kV Ranger 2 Cable Termination (R2T28J2)

This guide provides step-by-step instructions for preparing the cable, installing the lug or connector, cleaning the cable insulation, and installing the R2T28J2 28kV Ranger 2 cable termination for indoor/outdoor applications. Ensure all apparatus is de-energized before starting.

Estimated time: 1h 30m

1. Verify Kit and Cable Compatibility

   Check the contents of the package to ensure they are complete and undamaged. Confirm that all components, including the cable, fit within the kit's specified range (e.g., for R2T28J2, Dia. Over Insulation 0.84-1.38 inches (20-35mm), Dia. Over Jacket 1.72 inches (45mm) MAX).

2. De-energize Apparatus and Prepare Work Area

   Ensure all apparatus is de-energized during installation. Gather all required tools and maintain cleanliness throughout the procedure. This product should only be installed by competent personnel trained in good safety practices involving high voltage electrical equipment.

3. Train and Cut Cable

   Train the cable into its final position and cut it to the required length, ensuring sufficient neutral wire length for the grounding connection.

4. Prepare Cable Insulation and Jacket

   Prepare the cable according to the dimensions provided in the instructions, allowing for the depth of the terminal lug and additional exposed conductor distance for aluminum lugs (e.g., 2 inches (50mm) for #2-350, 1/4 inch (6mm) for 400-650, 1/2 inch (13mm) for 750-1000, 3/4 inch (19mm) for 1000+). For R2T28J2, Dimension A is 10.5 inches (270mm).

5. Apply First Mastic Band

   Using 50% stretch, carefully wrap one band of sealing mastic around the cable jacket 1/4 inch (6mm) from the jacket end. Position the mastic precisely as it serves as a marker for positioning the terminator. Cut the mastic flush without overlap.

6. Secure Neutral Wires

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

7. Apply Second Mastic Band

   Using 50% stretch, apply a second mastic band over the neutral wires and the previously applied mastic. Cut this band flush without overlap.

8. Seal Mastic with Vinyl Tape

   Wrap two half-lapped layers of vinyl tape around the mastic seal, carefully maintaining the 1/4 inch (6mm) dimension from the jacket end.

9. Prepare for Lug Installation (If Needed)

   If the chosen lug or connector will not fit through the termination core, clean the cable insulation and slide the termination body onto the cable before installing the lug. Do not remove the core at this time.

10. Install and Crimp Lug or Connector

    Position the connector or lug and crimp it according to the manufacturer's directions. Do not crimp the last 1/4 inch to 3/8 inch of the connector. After crimping, remove any excess oxide inhibitor and sharp crimp flashings.

11. Clean Cable Insulation

    Wipe the cable insulation with an approved solvent. Exercise caution to prevent the solvent from touching the semi-con insulation shield.

12. Abrasive Cleaning (If Necessary)

    If abrasive cleaning is necessary, use only aluminum oxide abrasive (grit 120 or finer) on the insulation only. Do not use abrasive on the semi-con insulation shield, and ensure the cable insulation diameter is not reduced below the kit's allowed range.

13. Apply First Silicone Tape Band

    Wrap a band of gray silicone rubber tape (from the kit) around the base of the terminal lug to create a track-resistant moisture seal. If the barrel diameter is smaller than the cable primary insulation, build up the tape band to equal the insulation diameter; otherwise, do not exceed two layers.

14. Apply Silicone Grease to Semi-Con Edge

    Apply a liberal coating of silicone grease to the edge of the semi-con insulation shield. This grease is crucial for filling the step at the semi-con cut-off and does not serve as a lubricant for the termination body.

15. Prepare Termination Core

    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.

16. Slide and Position Termination Body

    Slide the termination body onto the cable, aligning the terminator with the forward edge of the mastic seal (under the vinyl tape).

17. Remove Termination Core

    Carefully begin to remove the core by unwinding it counter-clockwise, starting with the loose end. Ensure the termination body, not the core, remains butted up to the leading edge of the mastic seal. Do not push or pull on the termination assembly while removing the core material.

18. Lubricate and Fold Down Skirt

    Apply a thin film of silicone lubricant to the skirt and mastic seal area, taking care to avoid the skirt tabs. Carefully fold down the skirt over the mastic seal.

19. Complete Lug Area Moisture Seal

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

20. Connect Neutral Wires to Ground

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

21. Verify High-K Step

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

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