ABB Installation Products R2T35J4-N0300 Ranger2 Termination for 35KV outdoor application, cable insulation diameter 1.30 - 2.10…

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How to Install the 35kV Ranger 2 Cable Terminator (R2T35J)

This guide provides step-by-step instructions for preparing the cable, installing the lug, and assembling the 35kV Ranger 2 Cable Terminator for indoor/outdoor applications on concentric and jacketed concentric neutral cables. Ensure all safety precautions are followed.

Estimated time: 1h 30m

1. De-energize Apparatus and Ensure Safety

   DANGER: All apparatus must be de-energized during installation or removal of parts. This product should be installed only by competent personnel trained in good safety practices involving high voltage electrical equipment. Failure to follow these instructions will result in damage to the product and serious or fatal injury.

2. 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 have all required tools at hand, maintaining cleanliness throughout the procedure.

3. Prepare Cable Length and Size

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

4. Prepare Cable Dimensions

   Prepare the cable using the dimensions provided in the instructions. Ensure to account for the depth of the terminal lug and provide additional exposed conductor distance to accommodate growth during crimping of aluminum lugs or connectors.

5. Apply First Mastic Band

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

6. 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.

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, ensuring no overlap.

8. Seal Mastic with Vinyl Tape

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

9. Install Lug or Connector

   If using a lug that does not fit through the termination core, slide the termination onto the cable first (without removing the core). Position the connector/lug and crimp it according to its specific directions, avoiding crimping the last 1/4” to 3/8” of the connector. Remove any excess oxide inhibitor and sharp crimp flashings after crimping.

10. Clean Cable Insulation and Lug Barrel

    Wipe the cable insulation with an approved solvent, ensuring the solvent does not touch the semi-con insulation shield. If abrasive cleaning is necessary, use only aluminum oxide abrasive (grit 120 or finer) on the insulation, avoiding the semi-con shield and taking care not to reduce the cable insulation diameter below the kit's allowance.

11. Apply Silicone Tape to Lug Base

    Wrap a band of gray silicone rubber tape 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, use the tape strip to build up the tape band to equal the insulation diameter.

12. Apply Silicone Grease to Semi-Con Shield

    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.

13. Prepare Lower Termination Core

    For the 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.

14. Install First Termination Half

    Slide the termination body onto the cable, aligning it with the forward edge of the mastic seal. Carefully remove the core by unwinding it counter-clockwise, starting with the loose end. Ensure the termination body, not the core, is firmly butted against the leading edge of the mastic seal. Do not push or pull the termination assembly during core removal.

15. Install Second Termination Half (if applicable)

    Using the second housing, carefully pull its core down within one coil of the bottom. Slide this terminator over the cable and carefully pull the core counter-clockwise. Overlap the first terminator by 1-1/2” (40mm).

16. Fold Down Skirt

    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.

17. 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” and extend the tape wrapping over a non-crimped region of the lug/connector barrel with a half-lap configuration.

18. Ground Neutral Wires

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

19. Verify High-K Step

    Confirm that the High-K step does not exceed 1.5” after installation.

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