ABB Installation Products R2T35M2N2250-B2 Outdoor, Ranger2 Termination, 35kV, Tape Shield/Wire Shield/UniShield Cable Type…

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How to Install the R2T35M 35kV Shrink-fit Silicone Rubber Termination

This guide provides detailed instructions for the safe and proper installation of the R2T35M 35kV Ranger 2 Shrink-fit Silicone Rubber Termination for indoor/outdoor applications with high-K stress relief on tape shield, wire shield, and UniShield® cables.

Estimated time: 1h 30m

1. De-energize and Prepare Cable

   DANGER: De-energize all apparatus in the work area before beginning installation. Verify the cable size fits within the insulation range specified in the Termination Selection Chart. Train the cable into position and cut to the required length. Prepare the cable using the specified dimensions, allowing for terminal lug depth and aluminum lug growth allowance. For tape shielded cables, hold down the tape shield edge with a single wrap of the supplied copper foil tape. For wire shielded cables, bend the leading 1-1/2" (38mm) of exposed shield wires back to the jacket edge. For UniShield® cables, install a constant force spring, pull shield wires through the semi-conductive jacket, remove the spring, bend UniShield® wires back 1" (25mm) onto the cable jacket, and remove the semi-conductive jacket to the specified dimension. Note: Some UniShield® cables have dual-layer semi-conductive jackets; both layers must be removed.

2. Install Ground Braid

   Wrap one band of mastic around the cable jacket 1/4” (6mm) from the jacket end using 50% stretch. Position the mastic carefully as it serves as a marker for termination positioning, then cut it flush without overlapping. Position the preformed ground braid with the short tail over the cable shield (tape, wire, or UniShield® wires) 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 into the mastic. Apply a second mastic band over the solder block and previously applied mastic, maintaining the 1/4” (6mm) dimension, using 50% stretch and cutting flush. Wrap two half-lapped layers of vinyl tape around the mastic seal, carefully maintaining the 1/4” (6mm) dimension. Wrap the ground braid around the cable 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) it after the final winding, and secure the spring with two wraps of vinyl tape. For cloth or paper semi-conductive insulation shields, overwrap the shield with one half-lapped layer of highly stretched semi-conductive rubber tape (e.g., Scotch® No. 13).

3. Install 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/lug and crimp it according to the manufacturer’s directions. Do not crimp the last 3/8” to 1/2” of the connector. Remove excess oxide inhibitor and all sharp crimp flashings and edges following crimping.

4. 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 an abrasive must be used, apply it only on the insulation (not the semi-conductive insulation shield), using only aluminum oxide abrasive (grit 120 or finer). Be careful not to reduce the cable insulation diameter below that allowed by the kit.

5. Install Termination Halves

   Create a track-resistant moisture seal between the termination insulator and the lug/connector using the gray silicone rubber electrical tape. Wrap a band of silicone tape around the base of the terminal lug. If the barrel diameter is smaller than the cable primary insulation, use the tape strip to form the tape band equal to the insulation diameter; if equal to or greater, the tape band should not exceed 2 layers. Liberally coat the edge of the semi-conductive insulation shield with 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, avoiding pushing or pulling on the termination assembly. If using a second housing, carefully pull its core down within 1 coil of the bottom. Slide this termination over the cable and carefully pull the core counterclockwise, overlapping the first termination by 1-1/2” (40mm). Apply a thin film of silicone lubricant to the skirt and mastic seal area (do not lubricate 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, overlapping the termination insulator by approximately 1” and extending 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 (for wire shielded cables, twist concentric neutral wires together and connect to system ground). Confirm that the High-K step does not exceed 1.5”.

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