EN 50483-4:2009
(Main)Test requirements for low voltage aerial bundled cable accessories - Part 4: Connectors
Test requirements for low voltage aerial bundled cable accessories - Part 4: Connectors
EN 50483 series applies to overhead line fittings for tensioning, supporting and connecting aerial bundled cables (ABC) of rated voltage U0/U (Um): 0,6/1 (1,2) kV. This Part 4 applies to connectors used for the electrical connection of ABC. The connectors are designed to be installed on ABC defined in HD 626. Tests described in this document are type tests. NOTE This European Standard does not invalidate existing approvals of products achieved on the basis of national standards and specifications and/or the demonstration of satisfactory service performance. However, products approved according to such national standards or specifications cannot directly claim approval to this European Standard. It may be possible, subject to agreement between supplier and purchaser, and/or the relevant conformity assessment body, to demonstrate that conformity to the earlier standard can be used to claim conformity to this standard, provided an assessment is made of any additional type testing that may need to be carried out. Any such additional testing that is part of a sequence of testing cannot be done separately.
Prüfanforderungen für Bauteile für isolierte Niederspannungsfreileitungen - Teil 4: Verbinder
EN 50483 (Reihe) gilt für oberirdisch zu verwendende Bauteile zum Abspannen, Aufhängen und Verbinden von iso¬lierten Freileitungen (en.: Aerial Bundled Cables, ABC) für eine Nennspannung von U0/U (Um): 0,6/1 (1,2) kV. Dieser Teil 4 gilt für Verbinder und Kabelanschlüsse (im Folgenden nur als Verbinder bezeichnet), die zum elektrischen Anschluss von ABC verwendet werden. Diese Verbinder sind für die Montage an ABC nach HD 626 ausgelegt. Die in diesem Dokument beschriebenen Prüfungen sind Typprüfungen. ANMERKUNG Durch diese Europäische Norm verlieren bestehende Zulassungen nicht ihre Gültigkeit, die auf der Basis nationaler Normen und Spezifikationen und/oder anhand des Nachweises zufriedenstellender Ergebnisse im Einsatz erfolgte. Jedoch gelten nach früheren Normen oder Spezifikationen zugelassene Produkte nicht als nach dieser Europäischen Norm zugelassen. Es ist möglich, basierend auf einer Vereinbarung zwischen Lieferanten und Auftraggeber und/oder der zuständigen Stelle für Konformitätsbewertungen, nachzuweisen, dass die Konformität mit der früheren Norm für den Anspruch auf Konformität mit dieser Norm verwendet werden kann, vorausgesetzt, eine Bewertung aller zusätzlichen Typprüfungen, deren Durchführung erforderlich sein könnte, ist erfolgt. Alle zusätzlichen Prüfungen, die Teil einer Prüffolge sind, dürfen nicht separat durchgeführt werden.
Prescriptions relatives aux essais des accessoires pour réseaux aériens basse tension torsadés - Partie 4: Connecteurs
La série EN 50483 s’applique aux équipements de lignes aériennes pour ancrage, suspension et raccordement des câbles torsadés aériens de tension assignée U0/U (Um): 0,6/1 (1,2) kV. Cette Partie 4 s’applique aux raccords utilises pour la connexion électrique des câbles torsadés aériens. Les raccords sont destinés à être installés sur les câbles torsadés aériens définis dans le HD 626. Les essais décrits dans ce document sont des essais de type. NOTE La présente Norme Européenne n’annule pas les approbations existantes des produits obtenues sur la base de normes ou spécifications nationales et/ou obtenues par la démonstration de performance satisfaisante en service. Cependant, des produits approuvés selon de telles normes ou spécifications nationales ne peuvent directement réclamer l’approbation à la présente Norme Européenne. Il peut être possible sous réserve, d’un accord entre le fournisseur et l’acheteur et/ou à l’organisme compétent d’évaluation de conformité, de démontrer que l’ancienne conformité peu être utilisée pour se réclamer de la conformité à la présente norme, pourvu qu’une évaluation soit faite à partir de tout essai additionnel de type qui pourrait être nécessaire. Un tel essai additionnel faisant partie d’une séquence d’essais ne peut être réalisé séparément.
Zahteve za preskušanje pribora za nizkonapetostne izolirane nadzemne kable - 4. del: Spojke
General Information
Relations
Standards Content (Sample)
SLOVENSKI STANDARD
01-julij-2009
Zahteve za preskušanje pribora za nizkonapetostne izolirane nadzemne kable - 4.
del: Spojke
Test requirements for low voltage aerial bundled cable accessories -- Part 4: Connectors
Prüfanforderungen für Bauteile für isolierte Niederspannungsfreileitungen – Teil 4:
Verbinder
Prescriptions relatives aux essais des accessoires pour réseaux aériens basse tension
torsadés -- Partie 4: Connecteurs
Ta slovenski standard je istoveten z: EN 50483-4:2009
ICS:
29.240.20 Daljnovodi Power transmission and
distribution lines
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
EUROPEAN STANDARD
EN 50483-4
NORME EUROPÉENNE
January 2009
EUROPÄISCHE NORM
ICS 29.240.20
English version
Test requirements for low voltage aerial bundled cable accessories -
Part 4: Connectors
Prescriptions relatives aux essais Prüfanforderungen für Bauteile für
des accessoires pour réseaux aériens isolierte Niederspannungsfreileitungen -
basse tension torsadés - Teil 4: Verbinder
Partie 4: Connecteurs
This European Standard was approved by CENELEC on 2008-12-01. CENELEC members are bound to comply
with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard
the status of a national standard without any alteration.
Up-to-date lists and bibliographical references concerning such national standards may be obtained on
application to the Central Secretariat or to any CENELEC member.
This European Standard exists in three official versions (English, French, German). A version in any other
language made by translation under the responsibility of a CENELEC member into its own language and notified
to the Central Secretariat has the same status as the official versions.
CENELEC members are the national electrotechnical committees of Austria, Belgium, Bulgaria, Cyprus, the
Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia,
Lithuania, Luxembourg, Malta, the Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain,
Sweden, Switzerland and the United Kingdom.
CENELEC
European Committee for Electrotechnical Standardization
Comité Européen de Normalisation Electrotechnique
Europäisches Komitee für Elektrotechnische Normung
Central Secretariat: avenue Marnix 17, B - 1000 Brussels
© 2009 CENELEC - All rights of exploitation in any form and by any means reserved worldwide for CENELEC members.
Ref. No. EN 50483-4:2009 E
Foreword
This European Standard was prepared by a sub-group of WG 11 of the Technical Committee
CENELEC TC 20, Electric cables.
The text of the draft was submitted to the formal vote and was approved by CENELEC as
EN 50483-4 on 2008-12-01.
The following dates were fixed:
– latest date by which the EN has to be implemented
at national level by publication of an identical
national standard or by endorsement (dop) 2009-12-01
– latest date by which the national standards conflicting
with the EN have to be withdrawn (dow) 2011-12-01
This is Part 4 of CENELEC standard EN 50483 “Test requirements for low voltage aerial
bundled cable accessories”, which has six parts:
– Part 1: Generalities;
– Part 2: Tension and suspension clamps for self supporting system;
– Part 3: Tension and suspension clamps for neutral messenger system;
– Part 4: Connectors;
– Part 5: Electrical ageing test;
– Part 6: Environmental testing.
__________
– 3 – EN 50483-4:2009
Contents
1 Scope . 4
2 Normative re f e r enc es . 4
3 Terms and definitions . 4
4 Symbols . 6
5 Characteristics . 6
6 Marking . 6
7 General test conditions . 7
7.1 Generalities . 7
7.2 Preconditioning of ABC . 7
8 Type tests . 8
8.1 IPC tests . 8
8.2 Pre-insulated through connectors (sleeve) . 25
8.3 Pre-insulated terminals (lugs) . 37
Annex A (informative) Temporary connectors – Temperature rise and overload test . 43
Bibliography . 47
Figures
Figure 1 – Test arrangement . 10
Figure 2 – Typical impact test arrangement . 14
Figure 3 – Illustrative arrangement for dielectrical test in water . 16
Figure 4 – Arrangement for dielectrical test in metallic balls . 17
Figure 5 – Typical arrangement for dielectrical test with metallic gauze . 18
Figure 6 – Test arrangement for the water tightness test . 20
Figure 7 – Orientation of the samples for the climatic ageing test . 24
Figure 8 – Illustrative installation of the mechanical test . 26
Figure 9 – Illustrative set up for dielectrical voltage test . 28
Figure 10 – Climatic ageing test arrangement . 31
Figure 11 – Illustrative set up of the testing assembly . 33
Figure 12 – Diagram of thermal cycles and mechanical stresses applied on phase
conductor. 34
Figure 13 – Diagram of thermal cycles and mechanical loads on neutral conductor . 36
Figure 14 – Illustrative installation of the mechanical test . 38
Figure 15 – Illustrative figure of immersed lug . 39
Figure 16 – Illustrative arrangement of immersion test in sodium hydroxide solution . 42
Figure A.1 – Example of a pin connection . 44
Figure A.2 – Test loop . 45
Tables
Table 1 – Initial loads required for marking . 26
Table 2 – Test loads. 26
Table 3 – Applied tensile load . 36
Table 4 – Tensile loads . 38
1 Scope
EN 50483 series applies to overhead line fittings for tensioning, supporting and connecting
aerial bundled cables (ABC) of rated voltage U /U (U ): 0,6/1 (1,2) kV.
0 m
This Part 4 applies to connectors used for the electrical connection of ABC.
The connectors are designed to be installed on ABC defined in HD 626.
Tests described in this document are type tests.
NOTE This European Standard does not invalidate existing approvals of products achieved on the basis of
national standards and specifications and/or the demonstration of satisfactory service performance. However,
products approved according to such national standards or specifications cannot directly claim approval to this
European Standard. It may be possible, subject to agreement between supplier and purchaser, and/or the relevant
conformity assessment body, to demonstrate that conformity to the earlier standard can be used to claim conformity
to this standard, provided an assessment is made of any additional type testing that may need to be carried out.
Any such additional testing that is part of a sequence of testing cannot be done separately.
2 Normative references
The following referenced documents are indispensable for the application of this document. For
dated references, only the edition cited applies. For undated references, the latest edition of
the referenced document (including any amendments) applies.
EN 50182:2001, Conductors for overhead lines – Round wire concentric lay stranded conductors
EN 50483 series, Test requirements for low voltage aerial bundled cable accessories
EN 60529:1991, Degrees of protection provided by enclosures (IP Code) (IEC 60529:1989)
HD 626, Overhead distribution cables of rated voltage U /U(U ): 0,6/1 (1,2) kV
o m
IEC 60050-461, International Electrotechnical Vocabulary (IEV) – Part 461: Electric cables
3 Terms and definitions
For the purposes of this document, the terms and definitions given in IEC 60050-461 and the
following apply.
3.1
aerial bundled cable (ABC)
aerial cable consisting of a group of insulated conductors which are twisted together including,
or not, a non insulated conductor
[IEV 461-08-02, modified]
NOTE The terms bundled conductors, bundled cables, bundled cores, conductor bundles and bundle could be
used as equivalent to the term aerial bundled cable (ABC).
3.2
aerial-insulated-cable
insulated cable designed to be suspended overhead and outdoors
[IEV 461-08-01]
– 5 – EN 50483-4:2009
3.3
branch connector
metallic device for connecting a branch conductor to a main conductor at an intermediate point
on the latter
[IEV 461-17-05]
3.4
branch conductor
conductor connected to the main conductor by a connector
3.5
conductor insulation
insulation applied on a conductor
[IEV 461-02-02, modified]
3.6
conductor (of a cable)
part of a cable which has the specific function of carrying current
[IEV 461-01-01]
3.7
connector
metallic device to connect cable conductors together
[IEV 461-17-03]
3.8
core
assembly comprising conductor and its own insulation
[IEV 461-04-04, modified]
3.9
insulation (of a cable)
insulating materials incorporated in a cable with the specific function of withstanding voltage
[IEV 461-02-01]
3.10
insulation piercing connector (IPC)
connector in which electrical contact with the conductor is made by metallic protrusions which
pierce the insulation of the ABC core
[IEV 461-11-08, modified]
3.11
messenger
wire or rope, the primary function of which is to support the cable in aerial installations, which
may be separate from or integral with the cable it supports
[IEV 461-08-03]
3.12
minimum breaking load (MBL)
minimum breaking load of the conductor given by HD 626 or the cable manufacturer if not
defined in the standard or minimum breaking load of the clamp given by the clamp
manufacturer
3.13
neutral messenger system
aerial insulated system where only the neutral messenger supports the ABC
3.14
pre-insulated (terminal) lug
insulated metallic device for connecting an insulated cable conductor to other electrical
equipment
3.15
pre-insulated through connector (sleeve)
insulated metallic device for connecting two consecutive lengths of insulated conductors
3.16
rated tensile strength (RTS)
estimate of the conductor breaking load calculated using the specified tensile properties of the
component wires
[EN 50182:2001, 3.7]
3.17
reusable connector
connector for connecting ABC to stripped cable or bare conductor where only the branch
connection can be reused
3.18
self supporting system
aerial insulated system where all the cores of the ABC contribute to its support
3.19
sheath
uniform and continuous tubular covering of metallic or non metallic material, generally extruded
[IEV 461-05-03]
3.20
shear head
head of a bolt, or a device fitted over the head of a bolt or a nut, which is designed to break at
a specified torque
3.21
type test
test required to be made before supplying a type of material covered by this standard on a
general commercial basis, in order to demonstrate satisfactory performance characteristics to
meet the intended application
NOTE These tests are of such a nature that, after they have been made, they need not be repeated unless
changes are made to the accessory materials, design or type of manufacturing process which might change the
performance characteristics.
4 Symbols
ρ resistivity (Ω.m)
5 Characteristics
These connectors shall connect cables designed to HD 626 and withstand the following type
tests.
6 Marking
See Clause 6 of EN 50483-1.
– 7 – EN 50483-4:2009
7 General test conditions
See Clause 9 of EN 50483-1.
7.1 Generalities
Minimum and maximum cross-sections of the conductors used for the tests shall be the
minimum and maximum cross-sections for which the connector is designed.
All conductors used in these tests shall be pre-conditioned in accordance with 7.2.
When tensile test loads are applied to conductors the rate of increase shall be in accordance
with EN 50483-1, 9.1.4.
A torque meter shall be used for all tightening operations and it shall have a resolution and
accuracy in accordance with EN 50483-1, 9.1.8.
All tests shall be carried out at ambient temperature unless otherwise stated in this standard.
The frequency of a.c. tests shall be in accordance with EN 50483-1, 9.1.1.
The relative humidity shall be in accordance with EN 50483-1, 9.1.9 unless otherwise altered
by this standard.
If a cable breaks beyond any part of a connector, the test result shall be declared void without
discrediting the connector. Tests can be repeated using a new connector and a new cable.
7.2 Preconditioning of ABC
New cores or cables shall be used.
Cores shall be pre-conditioned according to of EN 50483-1, 9.1 in order to ensure the
dimensional stabilisation of the insulating sheath.
The extremities of the service cables shall be installed into the connector in accordance with
the instructions given by the connector manufacturer.
For the voltage and water tightness tests in 8.1.3, if the connector is tested in horizontal
position, the cores shall first be bent and held in a rigid position using an appropriate device in
order to prevent damage to the connections during handling, as required in the specific test.
For the climatic ageing test in 8.1.5.2, the cores shall be bent as for the dielectrical voltage and
water tightness tests and their ends shall be tightly capped to prevent moisture from
penetrating the conductors, as required in the specific test.
When there is a requirement to bend the cables, the bending radius shall be at least 15 times
the outer diameter of the core.
NOTE 1 It is recommended that the cores should be shaped before installing the connectors.
NOTE 2 Cores used should comply with the piercing test of the insulating sheath defined in HD 626 where the
customer requires this and it is applicable to the type of cable being tested.
8 Type tests
8.1 IPC tests
8.1.1 Installation of IPCs
Connectors shall be installed in accordance with the manufacturer’s instructions. A torque
meter, in accordance with EN 50483-1, 9.1.8, shall be used for all tightening and untightening
operations.
Tightening shall be at the rate specified in EN 50483-1, 9.1.10.
The same core (e.g. Phase 1) of a cable with the same cross-section shall be used for each
test.
Connectors, used on cores with a cross-section lower than, or equal to, 35 mm², can be held in
position during tightening if necessary.
8.1.2 Mechanical testing
The following tests are designed to ensure that the IPC is both mechanically sound and does
not damage the conductors it connects:
Test Subclause
Test for mechanical damage to the main conductor 8.1.2.1
Branch cable pull-out test 8.1.2.2
Connector bolt tightening test 8.1.2.3
Shear head function test 8.1.2.4
Low temperature impact test 8.1.2.5
8.1.2.1 Test for mechanical damage to the main conductor
8.1.2.1.1 Principle
This test ensures that the mechanical performance of the conductor is not impaired as a
consequence of the installation of the IPC.
– 9 – EN 50483-4:2009
8.1.2.1.2 Test arrangement
Two samples shall be tested. Where the IPC is designed to accept more than one size of core,
2 samples shall be tested in each of the following conductor combinations:
Main Branch
max. max.
min. min.
min. max.
NOTE Where max. min. combination is required this may be agreed between the customer and the manufacturer.
The core shall be mounted in a tensile test machine in a suitable manner.
The core, on which the IPCs will be tested, shall be tensioned to between 10 % and 15 % of its
MBL for aluminium conductors (AAC) and between 15 % and 20 % of its MBL for all other
conductors as defined in HD 626 (for example copper and AAAC).
The core length shall be between 0,5 m and 1,5 m.
When using bare main conductors according to EN 50182 not included in HD 626, RTS shall
be used.
8.1.2.1.3 Procedure
Connectors shall be installed in accordance with the manufacturer’s instructions.
When the connector is designed with a shear-head, it shall be tightened to the manufacturer’s
specified maximum torque.
When the connector is designed without a shear-head, it shall be tightened to 1,1 times the
manufacturer’s specified nominal torque.
The connectors shall not be removed from the core before the mechanical tensile test.
A tensile test load shall be applied to the main conductor until it reaches the following values:
System type Conductor Tensile test load
Copper (4 mm² to 16 mm²) 20 % MBL of the cable
Copper (> 16 mm²) 80 % MBL of the cable
Self supporting
Aluminium (16 mm² to 25 mm²) 1 200 N or 40 % MBL of the cable,
whichever is the greater
Aluminium (> 25 mm²) 80 % MBL of the cable
Phase 60 % MBL of the cable
Neutral messenger
Neutral 90 % MBL of the cable
NOTE Loads for other designs of ABC shall be agreed between the customer and the manufacturer.
The load shall be maintained for 60 s.
8.1.2.1.4 Requirements
The conductor shall maintain the test load for 60 s without breaking or any damage that would
prevent the correct function of the cable.
8.1.2.2 Branch cable pull-out test
8.1.2.2.1 Principle
To ensure that the IPC provides mechanical security of the branch cable.
8.1.2.2.2 Test arrangement
Two samples shall be tested. Where the IPC is designed to accept more than one size of
conductor, two samples shall be tested in each of the following conductor combinations:
Main Branch
min. min.
max. min.
NOTE Where other combinations are required these may be agreed between the customer and the manufacturer.
The branch connector shall be positioned and then installed in accordance with the
manufacturer’s instructions.
The core lengths shall be between 0,2 m and 0,5 m.
The general arrangement is shown in Figure 1. The IPC shall be installed in accordance with
manufacturer’s instructions.
Key
1 branch
2 main secured in mechanical device
Figure 1 – Test arrangement
– 11 – EN 50483-4:2009
8.1.2.2.3 Procedure
When the connector is designed with a shear-head, it shall be tightened to the manufacturer’s
specified maximum torque.
When the connector is designed without a shear-head, it shall be tightened to 1,1 times the
manufacturer’s specified nominal torque.
The core, or in the case of a bare conductor, the conductor, shall be marked at the IPC so that
any slippage during the test can be measured.
A tensile load (F) shall be applied approximately axially, between the branch conductor and the
opposing main conductor which shall be secured in a mechanical device, at a rate between
100 N/min and 500 N/min. This load shall be 1 kN or 10 % of the MBL of the branch conductor
whichever is less.
The load shall be maintained for 60 s.
8.1.2.2.4 Requirements
Core slippage shall not exceed 3 mm.
The cores shall maintain the test load for 60 s without breaking or any damage that would
prevent the correct function of the cable.
8.1.2.3 Connector bolt tightening test
8.1.2.3.1 Principle
To ensure that when tightened, the bolts used to make the electrical connection and provide
mechanical security, do not cause the IPC to fail mechanically during installation.
8.1.2.3.2 Test arrangement
Two connectors shall be tested.
The core on to which the IPC is to be installed shall be tensioned to 20 % of its MBL.
The IPCs shall be installed on to cores for which it is designed. Where the IPC is designed to
accept more than one size of conductor, two samples shall be tested in each of the following
conductor combinations:
Main Branch
max. max.
min. min.
min. max.
NOTE Where max. min. combination is required this may be agreed between the customer and the manufacturer.
8.1.2.3.3 Procedure
The connectors shall be tightened, in accordance with EN 50483-1, 9.1.10, to the maximum
torque specified by the manufacturer, plus 20 %.
NOTE A higher value of torque may be used when this is agreed between customer and supplier.
8.1.2.3.4 Requirements
The connector shall be undamaged.
8.1.2.4 Shear head function test
8.1.2.4.1 Principle
To ensure that the shear head mechanism functions correctly within the specified torque range.
8.1.2.4.2 Test arrangement
Six samples shall be tested at each of the following temperatures:
• the minimum temperature shall be (-10 ± 3) °C;
• the maximum temperature shall be (50 ± 3) °C.
NOTE See EN 50483-1, 9.1, for information on the use of a lower temperature.
The samples shall be tested in either of the following cross-section combinations:
Main Branch
min. min.
max. max.
8.1.2.4.3 Procedure
The connector assemblies shall be placed in a temperature controlled environment until they
reach the test temperature. The temperature shall be maintained for a minimum of 15 min.
The assembly can be removed from the chamber and the torque applied outside. In this case
the temperature of the connector shall be monitored and the torque applied within the
temperature limits defined above.
The shear head shall then be tightened, in accordance with the manufacturer’s installation
instructions, until the head shears. This torque shall be recorded.
The test shall be repeated for the six samples at each of the specified temperatures and
cross-section combination.
8.1.2.4.4 Requirements
For each of the test temperatures and cross-section combination, the torque at which the shear
head shears, shall be within the tolerances of the manufacturer’s specified torque range.
– 13 – EN 50483-4:2009
8.1.2.5 Low temperature impact test
8.1.2.5.1 Principle
To ensure that the connector can withstand an impact when it is cold.
8.1.2.5.2 Test arrangement
Two connectors shall be installed in the manner for which they are designed.
The samples shall be tested in the following cross-section combinations:
Main Branch
max. min.
max. max.
Figure 2 shows a typical test arrangement.
The connectors and the cores shall be placed in a temperature controlled environment at
(-10 ± 3) °C until they reach the test temperature.
NOTE See EN 50483-1, 9.1, for information on the use of a lower temperature.
The assembly can be removed from the cold chamber in order to make the test. To ensure that
the test is carried out at the specified temperature the impact test shall be made immediately.
Dimensions in millimetres
Key
1 hammer 900 g 4 steel 10 kg
2 steel intermediate piece 100 g 5 slightly round edges
3 test piece
Figure 2 – Typical impact test arrangement
8.1.2.5.3 Procedure
The separate samples shall be placed in the impact test device and impacted with a cylindrical
anvil approximately 50 mm in diameter with a spherical contact radius of approximately
300 mm. The anvil shall have a mass of approximately 100 g and shall transfer to the test
sample the impact energy of a weight of 900 g falling freely through 200 mm.
Two impacts shall be made on each sample, one acting from the top and one acting on the
side.
NOTE 1 The position of impact should be agreed between the manufacturer and the customer as being the most
vulnerable points.
NOTE 2 The value of weight and distance of fall may be varied as long as the impact energy remains the same.
8.1.2.5.4 Requirements
No damage shall occur which would affect the correct function of the connector.
– 15 – EN 50483-4:2009
8.1.3 Dielectrical voltage tests and water tightness test
8.1.3.1 Dielectrical voltage test
This test is not applicable to IPC which connects a bare conductor to an insulated conductor.
In order to meet the requirements of the type tests at least one of the two dielectrical tests shall
be carried out.
Connector classes:
Class 1: connector subjected to dielectric test in water;
Class 2: connector subjected to dielectric test in air.
NOTE The choice of the class should be agreed between the manufacturer and the customer.
8.1.3.1.1 Principle
To ensure that the connector can withstand a dielectrical voltage.
8.1.3.1.2 Test arrangement
Two samples shall be tested. Where the IPC is designed to accept more than one size of
conductor, two samples shall be tested in each of the following conductor combinations:
Main Branch
min. min.
max. min.
8.1.3.1.3 Procedure
The connector shall be tightened to the minimum torque indicated by the manufacturer.
Initially, for reusable connectors, the tap core shall be successively, mounted four times and
removed three times.
Should the shear head break whilst mounting the connector then the torque shall be raised to
the minimum value according to the method defined in 8.1.1.
The mounting and removal shall entail taking the conductor out of the connector, but there
shall be no change in orientation, or modification of the stripped end of the conductor.
While mounting and removing the conductor, the bolts shall be tightened to the minimum
torque and then un-tightened.
8.1.3.1.3.1 Test in water (For Class 1 connectors only)
The assembly, of connector and cores, shall be placed at the bottom of a water tank. During
the movement of the assembly it may be supported to ensure no bending of the core or
unnecessary movement of the component parts.
The connector may be placed either vertically or horizontally.
The depth of water shall be measured from the upper part of the connector. The cores shall be
of such length to ensure that they are sufficiently above the water level to prevent flashover
(see Figure 3).
The maximum leakage current shall be in accordance with EN 50483-1, 9.1.5.
The resistivity ρ of the water used in this test shall be in accordance with EN 50483-1, 9.1.6.
The voltage shall be applied at a speed specified in EN 50483-1, 9.1.7.
After 30 min under water, the voltage test shall be applied to the sample with a 4 kV a.c. for
60 s according to Figure 3.
NOTE A voltage of 6 kV may be used when agreed between customer and manufacturer.
Dimensions in millimetres
Key
1 tank 5 part of connectors for watertight of tap core
2 insulated tap conductor 6 metallic electrode
3 insulated main conductor 7 water
4 mounted connector 8 watertight insulating cap or core bent so that
end is above the surface of water
Figure 3 – Illustrative arrangement for dielectrical test in water
– 17 – EN 50483-4:2009
8.1.3.1.3.2 Test in air (For Class 2 connectors only)
Two methods are provided; compliance with either will meet the requirements of this type test.
8.1.3.1.3.2.1 Method 1
The core shall not be bent near to the connector. Any change in orientation of the core shall be
at least 10 cm from the connector. The assembly shall be mounted so that the connectors lie
horizontally.
The assembly shall be covered by 1 cm to 2 cm of metallic balls with 1,3 mm to 1,7 mm
diameter. The metallic balls shall not apply undue mechanical stress to the assembly.
The test arrangement is shown in Figure 4.
Dimensions in millimetres
Key
1 insulated main conductor 5 mounted connector
2 tank 6 metallic electrode
3 insulated tap conductor 7 metallic balls
4 insulating cap
Figure 4 – Arrangement for dielectrical test in metallic balls
After a minimum period of 60 s, a voltage test of 4 kV a.c. shall be applied for 60 s between the
core conductors and the metallic balls.
NOTE 1 A voltage of 6 kV a.c. may be used when agreed between customer and manufacturer.
NOTE 2 A metallic foil may be used instead of metallic balls when agreed between the customer and
manufacturer.
The maximum leakage current shall be in accordance with EN 50483-1, 9.1.5.
The voltage shall be applied at a speed specified in EN 50483-1, 9.1.7.
8.1.3.1.3.2.2 Method 2
The assembled connectors shall be closely wrapped with metallic gauze having a mesh size
< 5 mm, which shall be clear of any test connections. If necessary these test points shall be
temporarily insulated.
NOTE 1 Figure 5 shows a typical test arrangement. Where the insulated end cap is incorporated into the design of
the connector it may be included within the gauze screen.
A test voltage of 4 kV a.c. shall be applied for 60 s between the main conductor and the gauze.
NOTE 2 A voltage of 6 kV a.c. may be used when agreed between customer and manufacturer.
For 10 min immediately preceding the test, and during the time the voltage is applied, the
connectors shall be exposed to artificial rain of characteristics defined in EN 60529:1991,
Class IPX3.
The maximum leakage current shall be in accordance with EN 50483-1, 9.1.5.
The voltage shall be applied at a speed specified in EN 50483-1, 9.1.7.
Key
1 metallic gauze 3 insulating cap
2 ABC cores 4 connector
Figure 5 – Typical arrangement for dielectrical test with metallic gauze
8.1.3.1.4 Requirements
No flashover or breakdown shall occur (tripping of voltage generator).
8.1.3.2 Water tightness test
This test is required for connectors for which the dielectric test in water is not applicable due to
the connector design.
– 19 – EN 50483-4:2009
8.1.3.2.1 Principle
To ensure that water cannot migrate to the ABC when it is used to connect the ABC to ABC or
to a bare conductor.
This test is applicable for insulated to bare conductors and for Class 2 connectors, if required.
8.1.3.2.2 Test arrangement
Two samples shall be tested. Where the connector is designed to accept more than one size of
conductor, two samples shall be tested in each of the following conductor combinations:
Main Branch
min. min.
min. max.
8.1.3.2.3 Procedure
Figure 6 shows the test arrangement.
The length of main cores shall be approximately 30 cm. The connectors shall be tightened to
the minimum torque specified by the manufacturer.
The assembly of connector and cores shall be placed at the bottom of a water tank. The depth
of water shall be measured above the core.
The tap core shall pass out of the tank through an appropriate seal, which shall be designed to
prevent any excessive stress on the insulation.
The assembly shall be left in the water for 24 h.
Dimensions in millimetres
Key
1 tank 4 bare or insulated main conductor
2 sealing 5 support if any
3 tap core 6 water
Figure 6 – Test arrangement for the water tightness test
8.1.3.2.4 Requirements
No trace of water shall be observed at the end of the core.
8.1.4 Low temperature assembly test
8.1.4.1 Principle
To ensure electrical contact is established when the IPC is applied in cold conditions.
– 21 – EN 50483-4:2009
8.1.4.2 Test arrangement
Two samples shall be tested. Where the IPC is designed to accept more than one size of
conductor, two samples shall be tested in each of the following conductor combinations:
NOTE Where min. min. combination is required this may be agreed between the customer and the manufacturer.
Main Branch
max. max.
min. max.
max. min.
8.1.4.3 Procedure
The connectors and core shall be further pre-conditioned until they reach the test temperature
of (-10 ± 3) °C, then they shall be assembled at this temperature in the cold chamber.
NOTE 1 See EN 50483-1, 9.1, for information on the use of a lower temperature.
Electrical continuity shall be measured between the main and branch cables.
The IPC shall be installed in accordance with the manufacturer’s instructions using a torque
meter.
Alternatively the assembly can be removed from the cold chamber and the torque applied
outside. In this case the temperature of the connector and the core shall be monitored and the
torque applied within the temperature limits defined above. This temperature shall be within
these limits once contact is made.
The torque at which continuity is achieved shall be recorded.
NOTE 2 Accuracy of torque meters is usually guaranteed at positive temperature ranges. Where the torque is
measured within the cold chamber the accuracy of the torque meter may not be guaranteed.
8.1.4.4 Requirements
Electrical continuity shall be achieved at a torque value less than, or equal to, 70 % of the
manufacturer’s specified minimum installation torque.
8.1.5 Environmental tests
In order to meet the requirements of the type tests at least one of the three corrosion tests (as
detailed in EN 50483-6, 8.4) and one of the two climatic tests (as detailed in EN 50483-6, 8.5)
shall be carried out.
The choice of the test shall be agreed between the manufacturer and the customer.
8.1.5.1 Corrosion tests
8.1.5.1.1 Principle
To ensure that the IPC is not affected in corrosive atmospheres.
8.1.5.1.2 Test arrangement - Salt mist test and gas atmosphere test
Two samples shall be tested in accordance with the following conductor combination:
Main Branch
min. min.
For immersion test see test arrangement in EN 50483-6, 8.4.3.1.
8.1.5.1.3 Procedure - Salt mist test and gas atmosphere test
The connector shall be placed in the middle of the main core of length 0,5 m to 1,5 m. It shall
be tightened to the minimum torque specified by the manufacturer.
For the immersion test see procedure in EN 50483-6, 8.4.3.1.
8.1.5.1.3.1 Salt mist test
The number of cycles shall be 4 (4 weeks) as defined in EN 50483-6, 8.4.1.
8.1.5.1.3.2 Gas atmosphere test
Method 1: Combined test. There shall be 4 cycles of 14 days. This 14-day cycle consists of
7 days of salt mist and 7 days in SO atmosphere as defined in of EN 50483-6, 8.4.1 and
EN 50483-6, 8.4.2.
Method 2: There shall be 500 cycles of 2 h (approximately 6 weeks).
8.1.5.1.3.3 Immersion test
See EN 50483-6, 8.4.3.
Method 1: There shall be 1 000 heat cycles in immersion as defined in EN 50483-6, 8.4.3.1.
Method 2: Method 2 is defined in EN 50483-6, 8.4.3.2, (included in the climatic ageing test
EN 50483-6, 8.5.1).
8.1.5.1.4 Requirements
Visual inspection shall be carried out and there shall be no significant trace of red rust.
NOTE Significant rusting would constitute more than 10 % of the exposed surface area of the metallic parts.
The sample’s identification marking shall be legible when examined with normal or corrected
vision, without magnification.
No deterioration of the connectors shall occur which would impair their normal function.
For a connector designed with a shear-head it shall be able to be removed with a torque below,
or equal to, the manufacturer’s specified maximum torque.
For a connector designed without a shear-head it shall be able to be removed with a torque
below or equal to 1,1 times the manufacturer’s specified nominal torque.
– 23 – EN 50483-4:2009
Additional test requirement for a connector which connects a bare conductor to an insulated
conductor are as follows:
A continuously increasing load shall be applied to the main conductor up to 90 % of the value
indicated in 8.1.2.1.
The load shall be increased in accordance with of EN 50483-1, 9.1.4.
The load shall be maintained for 60 s.
No breaking of the conductor strands shall be observed throughout the application of the load.
Additional test requirement for IPC submitted to immersion test, Method 1, are defined in
EN 50483-6, 8.4.3.1.
8.1.5.2 Climatic ageing test
NOTE It is recommended that these tests should be carried out on samples that have met the requirements of the
dielectrical voltage or water tightness tests.
8.1.5.2.1 Principle
To ensure that the connector is not affected by climatic conditions.
8.1.5.2.2 Test arrangement
See test arrangements of dielectrical voltage or water tightness as given in 8.1.3.
8.1.5.2.3 Procedure
8.1.5.2.3.1 Climatic ageing test - Method 1
There shall be 6 cycles of 1 week, as defined in EN 50483-6, 8.5.1.
The temperature during periods A and C shall be 70 °C.
NOTE The temperature may be lower if agreed between the customer and the manufacturer.
As far as possible, the samples shall be installed so that the axis of the main core is in a
horizontal plane and the lamp in a vertical plane. These two planes shall intersect in the middle
of the lamp and in the middle of the samples. The main core shall be orthogonal in the
described vertical plane. Half of the samples shall be installed as per orientation 1, the other as
per orientation 2 (see Figure 7).
ORIENTATION 1 ORIENTATION 2
Key
1 shear head 4 top view
2 front view 5 main cable
3 lamp
Figure 7 – Orientation of the samples for the climatic ageing test
8.1.5.2.3.2 Climatic ageing test - Method 2
There shall be 56 cycles of 1 day (8 weeks), as defined in EN 50483-6, 8.5.2.
The samples shall be installed in the orientation shown in Figure 7.
8.1.5.2.4 Requirements
After the climatic ageing cycles and after a period of at least 24 h but not exceeding 72 h at the
laboratory atmosphere, the samples shall meet the requirements of the following tests.
8.1.5.2.4.1 Test requirement for IPC
This test requirement is not applicable for connectors that connect a bare conductor to an
insulated conductor.
The IPC Class 1 and Class 2 shall meet the requirements of the dielectrical voltage test in air,
as given in 8.1.3.1.3.2.
For IPC Class 1 the assembly formed by the connector and the cores shall then taken out of
the metallic balls, without any mechanical stress, and shall meet the requirements of the
dielectrical voltage test in water as given in 8.1.3.1.3.1, but with a voltage of 1 kV.
– 25 – EN 50483-4:2009
8.1.5.2.4.2 Test requirement for a connector which connects a bare conductor to an
insulated conductor and for Class 2 connectors, if required
The connector shall meet the requirements of the water tightness test as given in 8.1.3.2, but
after an immersion time limited to 12 h.
8.1.5.2.4.3 Common test requirements
Visual inspection shall be carried out to determine that there has been no degradation of the
organic parts which could affect the normal function of the sample.
The sample’s identification marking shall be legible when examined with normal or corrected
vision, without magnification.
8.1.6 Electrical ageing test
Test procedures, requirements and classes are defined in EN 50483-5.
This test does not apply to IPC connectors used for measuring voltages and short-circuiting
ABC conductors to which the temperature rise and over-current tests are defined in Annex A.
8.2 Pre-insulated through connectors (sleeve)
8.2.1 Installation of connectors
Connectors shall be installed in accordance with the manufacturer’s instructions.
The same core (e.g. Phase 1) of a cable with the same cross-section shall be used for each
test.
For a connector designed for different cross-sections in the same side (e.g. bolted connectors),
the maximum and minimum cross-sections shall be tested; that is max. max. and min. min.
Where bolted connectors are to be tested, the test installation shall be made as defined in
8.1.1 for IPCs.
8.2.2 Mechanical testing
8.2.2.1 Principle
The purpose of this test is to ensure that the connector makes an acceptable mechanical
connection to the cable.
8.2.2.2 Test arrangement
Two samples shall be tested of each equal cross-section.
8.2.2.3 Procedure
The assembly shall be subjected to a tensile load applied to the conductor in accordance with
Figure 8.
When tensile test loads are applied to conductors the rate of increase shall be in accordance
with EN 50483-1, 9.1.4.
A tensile test load shall be applied to the conductor until it reaches the % MBL values of
Table 1:
Table 1 – Initial loads required for marking
4 mm² to 16 mm² Copper 10 % MBL for 60 s
16 mm² to 25 mm² Aluminium 20 % MBL for 60 s
Full tension:
Self supporting system
20 % of MBL for 60 s
2 2
35 mm to 150 mm Aluminium
Partial tension:
5 % of MBL for 60 s
Phases:
30 % MBL for 60 s
16 mm² to 150 mm² Aluminium
Neutral messenger system
Neutral:
60 % MBL for 60 s
25 mm² to 95 mm² Aluminium alloy
NOTE 1 Loads for other designs of ABC should be agreed between the customer and the manufacturer.
The cable shall be marked at the point at which it leaves the connector.
NOTE 2 For safety reason, the marking may be made either befor
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