Thomas & Betts R2T35M4 Installation Manual

IS--1144

IS--R2T35M

February 2011

Page 1 of 10

Installation Instructions

35kV Ranger 2 Shrink fit Silicone Rubber Termination

Indoor/Outdoor Application with High--K Stress Relief

for Tape shield, Wire Shield & UnishieldCables

Contents: 2--Silicone Rubber Termination Halves, Lubricant, 2--Strips Grey Silicone Rubber Tape, Constant Force Spring,

Optional Contents: Connector, Cable Support Bracket.

Preformed Ground Braid, 2--Strips Sealing Mastic,1--Strip Copper Foil Tape, 2--Gloves, Instruction Sheets.

DANGER

All apparatus must be de--energized during installation
or removal of part(s).

All apparatus must be installed and operated in
accordance with individual user,local, and national work
rules. These instructions do not attempt to provide for
every possible contingency.

Do not touch or move energized products.
Excess distortion of the assembled product may result in

its failure.
Inspect parts for damage, rating and compatibility with

mating parts.

FOR MORE INFORMATION ON PARTS, INSTALLATION RATINGS AND COMPATIBILITY, CALL THE NEAREST ELASTIMOLD OFFICE.

WARRANTY: Thomas & Betts warrants that this product will be free from defects in materials and workmanship for the period of two (2) years from the
date of shipment.Upon prompt notification of any warranted defect,Thomas & Betts will, at its option,repair, replace or refund thepurchase price. Proof
of purchase is required. Unauthorized modification or improper installation will void all warranties.
Limitations and Exclusions: THE ABOVE WARRANTY IS THE SOLE WARRANTY CONCERNING THIS PRODUCT, AND IS IN LIEU OF ALL
OTHER WARRANTIES EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MARCHATABILITY OR
FITNESS FOR A PARTICULARPURPOSE, WHICH ARE SPECIFICALLY DISCLAIMED. LIABILITY FOR BREACHOF THEABOVE WARRANTYIS
LIMITED TO COST OF REPAIR OR REPLACEMENT OF THE PRODUCT, AND UNDER NO CIRCUMSTANCES WILL THOMAS & BETTS BE
LIABLE FOR ANY INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES.

This product should be installed only by competent
personnel trained in good safety practices involving
high voltage electrical equipment. These instructions
are not intended as a substitute for adequate training or
experience in such safety practices.

Failure to follow these instructions will result in damage
to the product and serious or fatal injury.

If this product is supplied with a protective shipping
cover(s), remove this shipping cover(s) and replace with
the appropriate HV insulated cap(s) or connector(s)
before submerging or energizing the circuit.

IMPORTANT

1. Check contents of package to ensure they are complete
and undamaged.

2. Check all components to ensure proper fit with cable

and/or mating products.

3. Read entire installation instructions before starting.

4. Have all required tools at hand and maintain cleanliness
throughout the procedure.

Termination Selection Chart

Catalog

Number
R2T35M2 0.84--1.38 (20--35) 1.72 (45) MAX
R2T35M4

IS--1144
IS--R2T35M

February 2011
Printed in U.S.A.

Dia. Over Insulation

Inches (mm)

1.30--2.10 (35--55)

Tape Shield -- Page 2

Wire Shield -- Page 5

UniShield-- Page 8

Dia. Over Jacket

Inches (mm)

2.55 (65) MAX

Cable Support Bracket (Optional)

Typical 35kV

Cables
1/0--250 Kcmil*
350--1250 Kcmil*

8155 T&B Boulevard, Memphis, Tennessee 38125
(800) 888--0211 Fax: (800) 888-- 0690

Catalog
Number

* Confirm Cable Insulation Diameter

Overall Cable

Diameter

B1

B2

B3

is with the Range Listed

.800--1.250

20 -- 32mm

1.100--1.500
28 -- 38mm

1.450--1.950
37 -- 50mm

Bracket

Style

Single

Single

Double

IS--1144

February 2011
Page 2 of 10

Tape Shielded Cable

STEP 1 Prepare Cable

1. Check to be sure cable size fits within kit range as shown in the Termination Selection Chart, Page 1.

2. Train cable into position and cut to length required for installation.

3. Prepare cable using dimensions shown. Be sure to allow for depth of terminal lug. To prevent tape shield from unrolling,
hold down edge with a single wrap of the supplied copper foil tape as shown. Provide additional exposed conductor

distance to account for growth during crimping of ALUMINUM lugs or connectors as follows:

Aluminum Lug
Growth Allowance

2/0--350

1/4”(6mm)

400--650

1/2”(13mm)

750--1000

3/4”(19mm)

Jacket Removal Length

2”(50mm)

1”(25mm)

Cable Jacket

Tape Shield

13--1/2”(340mm)

Semi--Con

Insulation

Copper Foil Tape

Depth of

Terminal Lug

Plus Growth

Allowance

STEP 2 Install Ground Braid

1. Using 50% stretch, carefully wrap one (1) band of mastic around the cable jacket 1/4” (6mm) from jacket end as shown.

Position mastic carefully, it also serves as a markerfor positioning the terminator. Cut mastic flush, do not overlap.

2. Position preformed ground braid with short tail over tape shield and solder block centered over mastic strip. Secure ground
braid to cable jacket using vinyl tape. Press solder block into mastic. See figure below.

Cable Jacket

Vinyl Tape

Ground Braid

2--1/2”(64mm)

1/4” (6mm)

Solder Block

Semi--Con

Tape Shield

Mastic Seal

3. Using 50% stretch apply a second mastic band over the solder block and previously applied mastic maintaining the 1/4” (6mm)
dimension. Cut flush, do not overlap.

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

5. Wrap ground braid around cable tape shield one complete wrap, trim excess to prevent overlap and secure in place with
constant force spring. Wrap spring in same direction as ground braid. Cinch (tighten) the spring after wrapping the final
winding. Secure spring with two (2) wraps of vinyl tape.

SPECIAL NOTE FOR CLOTH OR PAPER SEMI--CON INSULATION SHIELD

In cable with cloth or paper semi--conductive shields it is recommended the shield be over wrapped

with one half--lapped layer of highly stretched semi--conductive rubber tape such as Scotcht No. 13.

2nd Mastic Seal

1/4” (6mm)

Vinyl Tape over Mastic

Vinyl Tape over Constant Force Spring

Constant Force Spring

Semi--Con

1” Min. Exposed

Semi--Con

Trim

Ground Braid

Cable Tape Shield

IS--1144

February 2011

Page 3 of 10

STEP 3 Install Lug or Connector

1. Check to insure termination assembly fits over the selected lug. If lug will not fit through the termination core, clean the
insulation and slide termination on cable before installing lug. Do not remove core at this time.

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

3/8” to 1/2” Uncrimped Length

STEP 4 Clean Cable Insulation and Lug Barrel Using Standard Practice

1. Wipe the cable insulation with an approved solvent. Do not allow solvent to touch semi--con insulation shield.

2. If abrasive must be used:
a. Use on insulation only. Do not use abrasive on semi--con insulation shield.
b. Use only aluminum oxide abrasive; grit 120 or finer.
c. Be careful not to reduce the cable insulation diameter below that allowed by the kit.

STEP 5 Install Termination

1. IMPORTANT: A track resistant moisture seal must be made between termination insulator and lug/connector using gray
silicone rubber electrical tape (contained in kit). Wrap a band of silicone tape around the base of the terminal lug.
a. If barrel diameter is equal to or greater than cable primary insulation, the tape band should not exceed 2 layers.
b. If barrel diameter is smaller than the cable primary insulation, use tape strip to form the tape band equal to

insulation diameter, see below.

2. Cover the edge of the semi--con insulation shield with a liberal coating of silicone grease. On this product the silicone
grease does not serve as a lubricant. It must be used to fill the step at the semi--con cut off.

Silicone Lubricant

Coils

3. On lower termination with fold down skirt pull looseend of removable core through top of termination until the core is flush with
bottom of the termination.

Removable core flush with bottom of the termination

4. Slide the termination body onto the cable, align terminator with forward edge of mastic seal as shown below. Carefully
begin to remove core while unwinding, counter--clockwise, starting with loose end. Make sure the terminator body, not the

core is butted up to the leading edge of the mastic seal, see below. Continue to remove core. Do not push or pull on
the termination assembly while removing core.

Mastic Seal

Silicone Tape

Pull Counter--clockwise

Align Terminator
with Leading Edge
of Mastic Seal

Mastic Seal Under
Vinyl Tape

IS--1144

February 2011
Page 4 of 10

5. Using second housing, carefully pull core down within 1 coil of bottom. Slidethe terminator over the cable and carefully pull the
core counterclockwise. Overlap the first terminator 1--1/2” (40mm).

1--1/2”(40mm) Housing Overlap

Pull to Remove Core

Proper gripping of termination and
removal of second core

6. Apply a thin film of silicone lubricant to the skirt and mastic seal area. Do not lubricate skirt tabs. Carefully fold down skirt over
mastic seal.

Apply Silicone Lubricant

Skirt Tab

Silicone Rubber Tape

Fold Down Skirt

7. With termination installed, complete the lug area moisture seal using the remaining gray silicone rubber electrical tape.
Overlap the termination insulator by approximately 1” and extend the tape wrapping over a non--crimped region of the lug/
connector barrel with half lap configuration. See above.

8. Connect ground braid to system ground.

High--K Step should overlap Cable Semi--Con

Silicone Rubber Tape

Not to Exceed 1.5”

9. Confirm that High--K step does not exceed 1.5”.

IS--1144

February 2011
Page 5 of 10

Wire Shielded Cable

STEP 1 Prepare Cable

1. Check to be sure cable size fits within kit range as shown in the Termination Selection Chart, Page 1.

2. Train cable into position and cut to length required for installation.

3. Prepare cable using dimensions shown. Be sure to allow for depth of terminal lug. Provide additional exposed

conductor distance to account for growth during crimping of ALUMINUM lugs or connectors as follows:

Aluminum Lug
Growth Allowance

4. Bend leading 1--1/2“ (38mm) of exposed shield wires back upon themselves to jacket edge.

Shield Wires

2”(50mm)

Cable Jacket

2--350

1/4”(6mm)

Jacket Removal Length

Semi--Con

400--650

1/2”(13mm)

13--1/2”(340mm)

Insulation

750--1000

3/4”(19mm)

Depth of

Terminal Lug

Plus Growth

Allowance

1”(25mm)

2”(50mm)

Cable Jacket

Insulation

Shield Wires

STEP 2 Install Ground Braid

1. Using 50% stretch, carefully wrap one (1) band of mastic around the cable jacket 1/4”(6mm) from jacket end as shown.

Position mastic carefully, it also serves as a markerfor positioning the terminator. Cut mastic flush, do not overlap.

2. Position preformed ground braid with short tail over tape shield and solder block centered over mastic strip. Secure ground
braid to cable jacket using vinyl tape. Press solder block into mastic. See figure below.

Cable Jacket

Marker Tape

Ground Braid Solder Block

3. Using 50% stretch apply a second mastic band over the solder block and previously applied mastic maintaining the 1/4” (6mm)
dimension. Cut flush, do not overlap.

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

5. Wrap ground braid around cable tape shield one complete wrap, trim excess to prevent overlap and secure in place with
constant force spring. Wrap spring in same direction as ground braid. Cinch (tighten) the spring after wrapping the final
winding. Secure spring with two (2) wraps of vinyl tape.

2--1/2”(64mm)

1/4” (6mm)

Semi--Con

Shield Wires

Mastic Seal

2nd Mastic Seal

Vinyl Tape

Constant Force Spring

Semi--Con

1” Min. Exposed

Semi--Con

Cable Tape Shield

Vinyl Tape over Constant Force Spring

Trim

Ground Braid

IS--1144

February 2011
Page 6 of 10

STEP 3 Install Lug or Connector

1. Check to insure termination assembly fits over the selected lug. If lug will not fit through the termination core, clean the
insulation and slide termination on cable before installing lug. Do not remove core at this time.

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

3/8” to 1/2” Uncrimped Length

STEP 4 Clean Cable Insulation and Lug Barrel Using Standard Practice

1. Wipe the cable insulation with solvent saturated pads. Do not allow solvent to touch semi--con insulation shield.

2. If abrasive must be used:
a. Use on insulation only. Do not use abrasive on semi--con insulation shield.
b. Use only aluminum oxide abrasive; grit 120 or finer.
c. Be careful not to reduce the cable insulation diameter below that allowed by the kit.

STEP 5 Install Termination

1. IMPORTANT: A track resistant moisture seal must be made between termination insulator and lug/connector using gray
silicone rubber electrical tape (contained in kit). Wrap a band of silicone tape around the base of the terminal lug.
a. If barrel diameter is equal to or greater than cable primary insulation, the tape band should not exceed 2 layers.
b. If barrel diameter is smaller than the cable primary insulation, use tape strip to form the tape band equal to

insulation diameter, see below..

2. Cover the edge of the semi--con insulation shield with a liberal coating of silicone grease. On this product the
silicone grease does not serve as a lubricant. It must be used to fill the step at the semi--con cut off.

Silicone Lubricant Silicone Tape

Coils

3. On lower termination with fold down skirt pull looseend of removable core through top of termination until the core is flush with
bottom of the termination.

Removable core flush with bottom of the termination

4. Slide the termination body onto the cable, align terminator with forward edge of mastic seal as shownbelow. Carefullybegin to
remove core while unwinding, counter--clockwise, starting with loose end. Make sure the terminator body, not the core is

butted up to the leading edge of the mastic seal, see below. Continue to remove core. Do not push or pull on the
termination assembly while removing core.

Mastic Seal

Align Terminator
with Leading Edge
of Mastic Seal

Pull Counter--clockwise

Mastic Seal Under
Vinyl Tape

IS--1144

February 2011

Page 7 of 10

5. Using second housing, carefully pull core down within 1 coil of bottom. Slidethe terminator over the cable and carefully pull the
core counterclockwise. Overlap the first terminator 1--1/2” (40mm).

1--1/2”(40mm) Housing Overlap

Pull to Remove Core

Proper gripping of termination and
removal of second core

6. Apply a thin film of silicone lubricant to the skirt and mastic seal area. Do not lubricate skirt tab. Carefully fold down skirt over
mastic seal.

Apply Silicone Lubricant

Skirt Tab

Silicone Rubber Tape

Fold Down Skirt

7. With termination installed, complete the lug area moisture seal using the remaining gray silicone rubber electrical 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, see above.

8. Twist concentric neutral wires together and connect to system ground.

High--K Step should overlap Cable Semi--Con

Silicone Rubber Tape

Not to Exceed 1.5”

9. Confirm that High--K step does not exceed 1.5”.

IS--1144

February 2011
Page 8 of 10

UniShieldShield Cable

STEP 1 Prepare Cable

1. Check to be sure cable size fits within kit range as shown in the Termination Selection Chart, Page 1.

2. Train cable into position and cut to length required for installation.

3. Prepare cable using dimensions shown. Be sure to allow for depth of terminal lug. Provide additional exposed

conductor distance to account for growth during crimping of ALUMINUM lugs or connectors as follows:

Aluminum Lug
Growth Allowance

4. Install constant force spring and pull shield wires through semi--conductive jacket to leading edge of spring.

5. Remove constant force spring. Bend shield wires back upon cable jacket 1”(25mm). Cut excess shield wire and discard.

12--1/2”(318mm)

2--350

1/4”(6mm)

400--650

1/2”(13mm)

750--1000

3/4”(19mm)

Depth of Terminal

Lug Plus Growth

Allowance

Fold Back
Shield Wires

6. Remove semi--conductive jacket to dimension shown below.

Toease jacket removal, install constant force spring as shown and ring cut 80% through jacket. Remove jacket sections
by pulling against constant force spring. DO NOT BELL SEMI--CON JACKET. Remove constant force spring.

Some UniShieldcables feature dual--layer semi--conductive jackets. Both layers must be removed during cable preparation.

1”(25mm)

Fold Back Shield Wires

Shield Wires

13--1/2”(340mm)

1”(25mm)

11--1/2”(290mm)

1”(25mm)

Cut Line

Constant Force Spring

Semi--Conductive Jacket

Depth of Terminal

Lug Plus Growth

Allowance

Depth of Terminal

Lug Plus Growth

Allowance

STEP 2 Install Ground Braid

1. Using 50% stretch, carefully wrap one (1) band of mastic around the cable jacket 1/4”(6mm) from shield wire end as shown.

Position mastic carefully, it also serves as a markerfor positioning the terminator. Cut mastic flush, do not overlap.

2. Position preformed ground braid with short tail over tape shield and solder block centered over mastic strip. Secure ground
braid to cablejacket 4--1/2” (114mm) from cable semi--conedge using vinyl tape. Presssolder blockintomastic. See figure below.

2--1/2”(64mm)

Cable Jacket

1/4” (6mm)

Vinyl Tape

Ground Braid

3. Using 50% stretch apply a second mastic band over the solder block and previously applied mastic. Cut flush, do not overlap.

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

5. Wrap ground braid around cable shield wires one complete wrap, trim excess to prevent overlap and secure in place with
constant force spring. Wrap spring in same direction as ground braid. Cinch (tighten) the spring after wrapping the final winding.

2nd Mastic Seal

Vinyl Tape

Solder Block

Constant Force Spring

Semi--Con

Vinyl Tape over Constant Force Spring

Shield Wires

Mastic Seal

Semi--Con

Trim

Ground Braid

Cable Wire Shield

IS--1144

February 2011

Page 9 of 10

STEP 3 Install Lug or Connector

1. Check to insure termination assembly fits over the selected lug. If lug will not fit through the termination core, clean the
insulation and slide termination on cable before installing lug. Do not remove core at this time.

2. Position connector/lug and crimp according to manufacturer’s directions. Remove excess oxide inhibitor and sharp crimp
flashings following crimping.

3/8” to 1/2” Uncrimped Length

STEP 4 Clean Cable Insulation and Lug Barrel Using Standard Practice

1. Wipe the cable insulation with solvent saturated pads. Do not allow solvent to touch semi--con insulation shield.

2. If abrasive must be used:
a. Use on insulation only. Do not use abrasive on semi--con insulation shield.
b. Use only aluminum oxide abrasive; grit 120 or finer.
c. Be careful not to reduce the cable insulation diameter below that allowed by the kit.

STEP 5 Install Termination

1. IMPORTANT: A track resistant moisture seal must be made between termination insulator and lug/connector using gray
silicone rubber electrical tape (contained in kit). Wrap a band of silicone tape around the base of the terminal lug.
a. If barrel diameter is equal to or greater than cable primary insulation, the tape band should not exceed 2 layers.
b. If barrel diameter is smaller than the cable primary insulation, use tape strip to form the tape band equal to

insulation diameter, see below.

2. Cover the edge of the semi--con insulation shield with a liberal coating of silicone grease. On this product the silicone grease
does not serve as a lubricant. It must be used to fill the step at the semi--con cut off.

Silicone Lubricant

Coils

3. On lower termination with fold down skirt pull looseend of removable core through top of termination until the core is flush with
bottom of the termination.

Removable core flush with bottom of the termination

4. Slide the termination body onto the cable, align terminator with forward edge of mastic seal as shown below. Carefully
begin to remove core while unwinding, counter--clockwise, starting with loose end. Make sure the terminator body, not the

core is butted up to the leading edge of the mastic seal, see below. Continue to remove core. Do not push or pull on
the termination assembly while removing core.

Pull Counter--clockwise

Align Terminator
with Leading Edge
of Mastic Seal

Mastic Seal Under
Vinyl Tape

IS--1144

February 2011
Page 10 of 10

5. Using second housing, carefully pull core down within 1 coil of bottom. Slide the terminator over thecable and carefullypull the
core counterclockwise. Overlap the first terminator 1--1/2” (40mm).

1--1/2”(40mm) Housing Overlap

Pull to Remove Core

Proper gripping of termination and
removal of second core

6. Apply a thin film of silicone lubricant to the skirt and mastic seal area. Carefully fold down skirt over mastic seal.

Apply Silicone Lubricant

Skirt Tab

Silicone Rubber Tape

Fold Down Skirt

7. With termination installed, complete the lug area moisture seal using the remaining gray silicone rubber electrical 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, see above.

8. Connect ground braid to system ground.

High--K Step should overlap Cable Semi--Con

Silicone Rubber Tape

Not to Exceed 1.5”

9. Confirm that High--K step does not exceed 1.5”.

8155 T&B Boulevard, Memphis, Tennessee 38125
(800) 888--0211 Fax: (800) 888-- 0690