ABB Installation Products R2T35J4-N0440 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 installing the 35kV Ranger 2 Cable Terminator for indoor/outdoor applications on concentric and jacketed concentric neutral cables, including cable preparation, lug installation, and termination assembly. Ensure all apparatus is de-energized before starting.

Estimated time: 1h 30m

1. Prepare for Installation and Safety Check

   DANGER: Ensure all apparatus is de-energized before installation or removal of parts. Inspect all kit contents for completeness and damage. Verify that all components are compatible with your cable and/or mating products. Read the entire installation instructions before beginning and have all required tools and supplies at hand. Wear the provided gloves throughout the procedure.

2. Prepare the Cable

   Confirm that your cable size fits within the kit's specified range. Train the cable into its final position and cut it to the required length, ensuring sufficient neutral wire length for grounding. Prepare the cable according to the dimensions provided in the diagram, allowing for the depth of the terminal lug and additional exposed conductor distance for aluminum lugs/connectors (e.g., 1/4" for #1-350 kcmil, 1/2" for 400-650 kcmil, 3/4" for 750-1000 kcmil).

3. Apply Mastic and Secure Neutral Wires

   Using 50% stretch, carefully wrap one band of sealing mastic around the cable jacket 1/4" (6mm) from the jacket end. Position it precisely as it serves as a terminator marker, then cut the mastic flush without overlapping. Bend the neutral wires back over the mastic and press them into it, securing them to the cable jacket 4-6" (100-150mm) from the cut edge using vinyl tape or binding wire. Apply a second mastic band over the neutral wires and the first mastic band, again using 50% stretch and cutting flush. Finally, wrap two half-lapped layers of vinyl tape around the mastic seal, carefully maintaining the 1/4" (6mm) dimension.

4. Install the Lug or Connector

   The termination assemblies are designed for use with Elastimold copper or aluminum lugs. If other lugs are used and 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 yet). Position the connector or lug and crimp it according to its specific directions, ensuring not to crimp the last 1/4" to 3/8" of the connector. After crimping, remove any excess oxide inhibitor and sharp crimp flashings.

5. Clean Cable Insulation and Lug Barrel

   Wipe the cable insulation thoroughly with an approved solvent, taking care not to let the solvent 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 the kit's allowed range.

6. Prepare for Termination Installation

   IMPORTANT: Create a track-resistant moisture seal by wrapping a band of gray silicone rubber tape (from the kit) around the base of the terminal lug. If the barrel diameter is equal to or greater than the cable primary insulation, do not exceed two layers of tape. If the barrel diameter is smaller, use the tape strip to build up the tape band to equal the insulation diameter. Apply a liberal coating of silicone grease to the edge of the semi-con insulation shield to fill the step at the semi-con cut-off.

7. Install the Lower Termination Half

   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. Slide the termination body onto the cable, aligning the terminator with the forward edge of the mastic seal. 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. Do not push or pull on the termination assembly while removing the core material.

8. Install the Upper Termination Half

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

9. Complete Skirt and Lug Area Seal

   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 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.

10. Ground Neutral Wires and Final Check

    Twist the concentric neutral wires together and connect them securely to the system ground. Finally, confirm that the High-K step does not exceed 1.5" (38mm) to ensure proper electrical performance and safety.

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