ABB Installation Products R2T35M2N2240 Ranger2 Termination for 35KV outdoor application, cable insulation diameter .84 - 1.38…

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How to Install the 35kV Ranger 2 Shrink-fit Silicone Rubber Termination (R2T35M)

This guide provides step-by-step instructions for the safe and proper installation of the 35kV Ranger 2 Shrink-fit Silicone Rubber Termination on high voltage electrical cables, including cable preparation, ground braid installation, and termination application.

Estimated time: 1h 30m

1. Prepare for Installation and Ensure Safety

   DANGER: De-energize all apparatus in the work area before beginning installation. Do not touch or move energized products. Ensure installation is performed by competent personnel trained in high voltage electrical equipment safety practices. Verify the kit contents are complete and undamaged. Check all components for proper fit with the cable and mating products. Gather all required tools and maintain cleanliness throughout the procedure.

2. Prepare the Cable

   Confirm the cable size fits 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 the depth of the terminal lug and any growth allowance for aluminum lugs. Remove the cable jacket to the specified length (e.g., 13-1/2 inches (340mm) for tape shield). If using tape shield cable, prevent the tape shield from unrolling by holding down its edge with a single wrap of the supplied copper foil tape. For aluminum lugs, provide additional exposed conductor distance: 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

   Carefully wrap one band of mastic around the cable jacket 1/4 inch (6mm) from the jacket end, using 50% stretch. Cut the mastic flush without overlap. This band also serves as a termination positioning marker. Position the preformed ground braid with the short tail over the tape shield and the solder block centered over the mastic strip. Secure the ground braid to the cable jacket with vinyl tape and press the solder block into the mastic. Apply a second mastic band over the solder block and the first mastic band, maintaining the 1/4 inch (6mm) dimension and using 50% stretch. Cut flush, do not overlap. 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) it after the final winding, and secure it with two wraps of vinyl tape. SPECIAL NOTE: For cloth or paper semi-con insulation shields, overwrap the shield with one half-lapped layer of highly stretched semi-conductive rubber tape (e.g., Scotch® No. 13).

4. Install the Terminal Lug or Connector

   Verify that the termination assembly can fit over the selected lug. If not, 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 instructions. 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 after crimping.

5. Clean Cable Insulation and Lug Barrel

   Wipe the cable insulation with an approved solvent, ensuring 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 only. Do not use abrasive on the semi-conductive insulation shield. Be careful not to reduce the cable insulation diameter below the kit's allowed range.

6. Install the Termination Halves

   Create a track-resistant moisture seal between the termination insulator and the lug/connector by wrapping a band of gray silicone rubber electrical tape around the base of the terminal lug. If the barrel diameter is smaller than the cable primary insulation, use the tape strip to build up the band 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. 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 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. Ensure the termination body, not the core, is butted up to the leading edge of the mastic seal. Continue removing the core without pushing or pulling the termination assembly. Using the second housing, carefully pull its core down to within 1 coil of the bottom. Slide this termination over the cable and carefully pull the core counter-clockwise. Overlap the first termination by 1-1/2 inches (40mm). Apply a thin film of silicone lubricant to the skirt and mastic seal area, avoiding 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 and extend the tape wrapping over a non-crimped region of the lug/connector barrel with a half-lap configuration.

7. Connect Ground and Verify

   Connect the ground braid to the system ground. Confirm that the High-K step does not exceed 1.5 inches.

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