ABB Installation Products R2T28M2-N0260 Ranger2 Termination for 25/28KV outdoor application, cable insulation diameter .84…

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How to Install the R2T28M2 Shrink-fit Silicone Rubber Termination

This guide provides detailed instructions for installing the 28kV Ranger 2 Shrink-fit Silicone Rubber Termination (R2T28M2) on tape shield cables, covering cable preparation, ground braid installation, lug connection, and termination placement.

1. Preparation and Safety Check

   De-energize all apparatus in the work area before beginning installation. Inspect the kit contents for completeness and damage, and verify all components fit the cable and mating products. Gather all required tools and maintain cleanliness throughout the procedure. Ensure installation is performed only by competent personnel trained in good safety practices involving high voltage electrical equipment.

2. Prepare the Cable

   Confirm the cable size is within the termination's insulation range as shown in the Termination Selection Chart. Train the cable into its final position and cut it to the required length for installation. Prepare the cable using the dimensions provided in Table 1 for jacket removal length, allowing for the depth of the terminal lug and additional exposed conductor distance for growth during crimping of aluminum lugs or connectors. To prevent the tape shield from unrolling, hold down its edge with a single wrap of the supplied copper foil tape.

3. Install the Ground Braid

   Carefully wrap one band of sealing mastic around the cable jacket, 1/4 inch (6mm) from the jacket end, using 50% stretch. Position the mastic carefully as it also serves as a marker for the termination. Cut the mastic flush without overlap. 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 mastic band (50% stretch) over the solder block and the previously applied mastic, maintaining the 1/4 inch (6mm) dimension, and 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 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 spring after wrapping the final winding, and secure it with two wraps of vinyl tape.

4. Install the Terminal Lug or Connector

   Check to ensure the termination assembly fits over the selected lug. If the lug 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 or lug and crimp it according to the manufacturer’s directions. Do not crimp the last 3/8 inch to 1/2 inch of the connector. Remove any excess oxide inhibitor and all sharp crimp flashings and edges following crimping.

5. Clean Cable Insulation and Lug Barrel

   Wipe the cable insulation with an approved solvent. Do not allow solvent to touch the semi-conductive insulation shield. If an abrasive must be used, apply it only to the insulation, not the semi-conductive insulation shield. Use only aluminum oxide abrasive, grit 120 or finer, and be careful not to reduce the cable insulation diameter below that allowed by the kit.

6. Install the Termination Body

   Create a track-resistant moisture seal between the termination insulator and the lug/connector using the gray silicone rubber electrical tape from the kit. Wrap a band of silicone tape around the base of the terminal lug; 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. Cover the edge of the semi-conductive insulation shield with a liberal coating of silicone grease to fill the step at the semi-con cut-off. On 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. Slide the termination body onto the cable, aligning it with the forward edge of the mastic seal. 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. Continue to remove the core, but do not push or pull on the termination assembly while removing it.

7. Complete 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. With the termination installed, complete the lug area moisture seal using the remaining gray silicone rubber electrical tape. 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. Connect the ground braid to the system ground. Finally, confirm that the High-K step does not exceed 1.5 inches.

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