IEC 61238-1-1:2018

Compression and mechanical connectors for power cables - Part 1-1: Test methods and requirements for compression and mechanical connectors for power cables for rated voltages up to 1 kV (U_m = 1,2 kV) tested on non-insulated conductors

IEC 61238-1-1:2018 applies to compression and mechanical connectors for power cables for rated voltages up to 1 kV (Um = 1,2 kV), for example buried cables or cables installed in buildings, having
a) conductors complying with IEC 60228 having nominal cross-sectional areas between 2,5 mm2 and 1 200 mm2 for copper and between 16 mm2 and 1 200 mm2 for aluminium;
b) a maximum continuous conductor temperature not exceeding 90 °C.
This document is not applicable to connectors for overhead line conductors nor to connectors with a sliding contact.
The object of this document is to define the type test methods and requirements which apply to compression and mechanical connectors for power cables with copper or aluminium conductors. The reference method is to perform the tests on unused conductors.
This first edition, together with IEC 61238-1-2 and IEC 61238-1-3, cancels and replaces IEC 61238-1:2003.
This edition includes the following significant technical changes with respect to IEC 61238-­1:2003:
a) The scope has been widened to cover connectors for copper conductors from 10 mm2 down to 2,5 mm2 and has been limited to 1 200 mm2 for connectors for copper and aluminium conductors because test experience and applications are rare for conductors of larger cross-sectional areas.
b) Two new mechanical classes have been introduced to satisfy the demand for connectors subjected to no mechanical force and for connectors subjected to higher mechanical forces than those specified in Class 1 for conductors of larger cross-sectional areas.
c) For the electrical test, a maximum elevated heating current has been set in order to avoid unrealistic current densities during testing which may change properties of tested connectors.
d) For the short-circuit test, the method of calculation and requirements have been updated.
e) For the mechanical test, the methods and requirements have been updated.

Raccords sertis et à serrage mécanique pour câbles d'énergie – Partie 1-1: Méthodes et exigences d’essai relatives aux raccords sertis et à serrage mécanique pour câbles d’énergie de tensions assignées inférieures ou égales à 1 kV (U_m = 1,2 kV) soumis à essai sur des conducteurs non isolés

L'IEC 61238-1-1:2018 est applicable aux raccords sertis et à serrage mécanique pour câbles d'énergie de tensions assignées inférieures ou égales à 1 kV (Um = 1,2 kV), par exemple pour les câbles enterrés ou ceux installés à l'intérieur des bâtiments, ayant
a) des âmes conformes à l'IEC 60228, de section nominale comprise entre 2,5 mm2 et 1 200 mm2 pour le cuivre et entre 16 mm2 et 1 200 mm2 pour l'aluminium;
b) une température maximale de fonctionnement en service permanent au plus égale à 90 °C.
Le présent document n'est pas applicable aux raccords pour conducteurs de ligne aérienne ni aux raccords équipés d'un contact glissant.
L'objet du présent document est de définir les méthodes d'essais de type et les exigences qui s'appliquent aux raccords sertis et à serrage mécanique utilisables sur les câbles d'énergie à conducteurs en cuivre ou en aluminium. La méthode de référence consiste à réaliser les essais sur des conducteurs neufs.
Cette première édition, conjointement avec l'IEC 61238-1-2 et l'IEC 61238-1-3, annule et remplace l'IEC 61238-1:2003.
Cette édition inclut les modifications techniques majeures suivantes par rapport à l'IEC 61238-1:2003:
a) Le domaine d'application a été élargi afin de couvrir les raccords de connexion pour âmes en cuivre jusqu'à 2,5 mm2 (précédemment 10 mm2) et il a été limité à 1 200 mm2 pour les raccords utilisables sur les âmes en cuivre et en aluminium car les expériences et applications d'essai sont rares pour les âmes de fortes sections.
b) Deux nouvelles classes mécaniques ont été introduites pour répondre à la demande concernant les raccords non soumis aux forces mécaniques ainsi que les raccords soumis à des forces mécaniques supérieures à celles spécifiées en Classe 1 pour les âmes de fortes sections.
c) Pour l'essai électrique, un courant de chauffage maximal élevé a été défini afin d'éviter l'apparition de densités de courant irréalistes pendant l'essai, qui peuvent modifier les propriétés des raccords en essai.
d) Pour l'essai de court-circuit, la méthode de calcul et les exigences ont été mises à jour.
e) Pour l'essai mécanique, les méthodes et exigences ont été mises à jour.

General Information

• Status: Published
• Publication Date: 07-May-2018
• ICS: 01 - GENERALITIES. TERMINOLOGY. STANDARDIZATION. DOCUMENTATION
• ICS: 29.060.20 - Cables
• Technical Committee: TC 20 - Electric cables
• Drafting Committee: WG 16 - TC 20/WG 16
• Current Stage: PPUB - Publication issued
• Start Date: 25-May-2018
• Completion Date: 08-May-2018

Relations

• Replaces: IEC 61238-1:2003 - Compression and mechanical connectors for power cables for rated voltages up to 30 kV (Um = 36 kV) - Part 1: Test methods and requirements
• Effective Date: 05-Sep-2023

Standards Content (Sample)

IEC 61238-1-1 ®
Edition 1.0 2018-05
INTERNATIONAL
STANDARD
Compression and mechanical connectors for power cables –
Part 1-1: Test methods and requirements for compression and mechanical
connectors for power cables for rated voltages up to 1 kV (U = 1,2 kV) tested on
m
non-insulated conductors
All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized in any form
or by any means, electronic or mechanical, including photocopying and microfilm, without permission in writing from
either IEC or IEC's member National Committee in the country of the requester. If you have any questions about IEC
copyright or have an enquiry about obtaining additional rights to this publication, please contact the address below or
your local IEC member National Committee for further information.

IEC Central Office Tel.: [phone]
3, rue de Varembé [e-mail]
CH-1211 Geneva 20 www.iec.ch
Switzerland
About the IEC
The International Electrotechnical Commission (IEC) is the leading global organization that prepares and publishes
International Standards for all electrical, electronic and related technologies.

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IEC 61238-1-1 ®
Edition 1.0 2018-05
INTERNATIONAL
STANDARD
Compression and mechanical connectors for power cables –

Part 1-1: Test methods and requirements for compression and mechanical

connectors for power cables for rated voltages up to 1 kV (U = 1,2 kV) tested on
m
non-insulated conductors
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
ICS 29.060.20 ISBN 978-2-8322-5645-9

– 2 – IEC 61238-1-1:2018 © IEC 2018
CONTENTS
FOREWORD . 4
INTRODUCTION . 6
1 Scope . 7
2 Normative references . 7
3 Terms and definitions . 7
4 Symbols . 9
5 General . 10
5.1 Definition of classes . 10
5.2 Conductor . 11
5.3 Connectors and installation procedure . 11
5.4 Range of approval. 11
6 Electrical tests . 12
6.1 Installation . 12
6.1.1 General . 12
6.1.2 Through connectors and terminations . 13
6.1.3 Branch connectors . 13
6.2 Measurements . 13
6.2.1 General . 13
6.2.2 Electrical resistance measurements . 14
6.2.3 Temperature measurements . 14
6.3 Heat cycling test . 14
6.3.1 General . 14
6.3.2 First heat cycle . 15
6.3.3 Second heat cycle . 15
6.3.4 Subsequent heat cycles . 17
6.4 Short-circuit test for connectors according to Class A . 17
6.4.1 General . 17
6.4.2 Aluminium conductors with cross-sectional areas below 1 000 mm and
copper conductors with cross-sectional areas below 630 mm . 18
6.4.3 Aluminium conductors with cross-sectional areas ≥ 1 000 mm and
copper conductors with cross-sectional areas ≥ 630 mm . 18
6.5 Assessment of results . 19
6.6 Requirements . 19
6.7 Examples of electrical test loop configurations and associated parameters . 19
7 Mechanical test . 25
7.1 General . 25
7.2 Method . 25
7.3 Requirements . 25
8 Test reports . 26
8.1 General . 26
8.2 Electrical tests . 26
8.3 Mechanical test . 26
Annex A (normative) Equalizers and their preparation . 27
A.1 Requirements for equalizers . 27
A.2 Recommendations for welding equalizers . 27
Annex B (normative) Measurements . 29

B.1 Potential measuring positions for typical connectors . 29
B.2 Temperature measurement . 29
B.3 Equivalent conductor resistance . 29
Annex C (informative) Recommendations to decrease uncertainties of measurement . 30
C.1 Handling the test loop . 30
C.2 Measurements, instruments and readings . 30
Annex D (normative) Calculation of adiabatic short-circuit current . 31
Annex E (informative) Determination of the value of the short-circuit current . 32
Annex F (normative) Calculation method . 33
F.1 General . 33
F.2 Measurements made . 33
F.3 Connector resistance factor k . 33
F.4 Initial scatter δ . 34
F.5 Mean scatter β . 34
F.6 Change in resistance factor of each connector . 36
F.6.1 General . 36
F.6.2 Line of best fit . 36
F.6.3 Confidence interval δ . 36
i
F.6.4 Change in resistance factor D . 37
F.7 Resistance factor ratio λ. 37
F.8 Maximum temperatures θ . 37
max
Annex G (informative) Explanation on assessment of results of electrical tests on
connectors . 38
G.1 History . 38
G.2 Short examination of the assessment methods of IEC 61238-1 compared

with the Italian standard CEI 20-28 and the British standard BS 4579-3 . 38
G.3 The IEC 61238-1 method of assessing test results . 39
Bibliography . 41

Figure 1 – Example of second heat cycle profile . 17
Figure 2 – Typical electrical test loops for through connectors and terminal lugs . 21
Figure 3 – Typical electrical test loop for branch connectors . 22
Figure 4 – Typical cases of resistance measurements . 24
Figure A.1 – Preparation of equalizers . 28
Figure E.1 – Determination of equivalent RMS value of current during the short-circuit test . 32
Figure F.1 – Graphic example of assessment of a Class A individual connector . 35

Table 1 – Minimum period of temperature stability . 15
Table 2 – Electrical resistance measurements during the electrical test . 17
Table 3 – Electrical test requirements . 19
Table 4 – Selection of tensile force withstand values for the mechanical test . 25
Table D.1 – Material properties . 31
Table G.1 – Summary of assessed behaviour of a tested connector . 40

– 4 – IEC 61238-1-1:2018 © IEC 2018
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
COMPRESSION AND MECHANICAL
CONNECTORS FOR POWER CABLES –
Part 1-1: Test methods and requirements for compression and
mechanical connectors for power cables for rated voltages up to 1 kV
(U = 1,2 kV) tested on non-insulated conductors
m
FOREWORD
1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising
all national electrotechnical committees (IEC National Committees). The object of IEC is to promote
international co-operation on all questions concerning standardization in the ele
...

IEC 61238-1-1 ®
Edition 1.0 2018-05
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Compression and mechanical connectors for power cables –
Part 1-1: Test methods and requirements for compression and mechanical
connectors for power cables for rated voltages up to 1 kV (U = 1,2 kV) tested
m
on non-insulated conductors
Raccords sertis et à serrage mécanique pour câbles d'énergie –
Partie 1-1: Méthodes et exigences d'essai relatives aux raccords sertis et à
serrage mécanique pour câbles d'énergie de tensions assignées inférieures ou
égales à 1 kV (U = 1,2 kV) soumis à essai sur des conducteurs non isolés
m
All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized in any form
or by any means, electronic or mechanical, including photocopying and microfilm, without permission in writing from
either IEC or IEC's member National Committee in the country of the requester. If you have any questions about IEC
copyright or have an enquiry about obtaining additional rights to this publication, please contact the address below or
your local IEC member National Committee for further information.

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About the IEC
The International Electrotechnical Commission (IEC) is the leading global organization that prepares and publishes
International Standards for all electrical, electronic and related technologies.

About IEC publications
The technical content of IEC publications is kept under constant review by the IEC. Please make sure that you have the
latest edition, a corrigenda or an amendment might have been published.

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The stand-alone application for consulting the entire The world's leading online dictionary of electronic and
bibliographical information on IEC International Standards, electrical terms containing 21 000 terms and definitions in
Technical Specifications, Technical Reports and other English and French, with equivalent terms in 16 additional
documents. Available for PC, Mac OS, Android Tablets and languages. Also known as the International Electrotechnical
iPad. Vocabulary (IEV) online.

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The advanced search enables to find IEC publications by a 67 000 electrotechnical terminology entries in English and
variety of criteria (reference number, text, technical French extracted from the Terms and Definitions clause of
committee,…). It also gives information on projects, replaced IEC publications issued since 2002. Some entries have been
and withdrawn publications. collected from earlier publications of IEC TC 37, 77, 86 and

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IEC 61238-1-1 ®
Edition 1.0 2018-05
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Compression and mechanical connectors for power cables –

Part 1-1: Test methods and requirements for compression and mechanical

connectors for power cables for rated voltages up to 1 kV (U = 1,2 kV) tested

m
on non-insulated conductors
Raccords sertis et à serrage mécanique pour câbles d'énergie –

Partie 1-1: Méthodes et exigences d'essai relatives aux raccords sertis et à

serrage mécanique pour câbles d'énergie de tensions assignées inférieures ou

égales à 1 kV (U = 1,2 kV) soumis à essai sur des conducteurs non isolés
m
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 29.060.20 ISBN 978-2-8322-6150-7

– 2 – IEC 61238-1-1:2018 © IEC 2018
CONTENTS
FOREWORD . 4
INTRODUCTION . 6
1 Scope . 7
2 Normative references . 7
3 Terms and definitions . 7
4 Symbols . 9
5 General . 10
5.1 Definition of classes . 10
5.2 Conductor . 11
5.3 Connectors and installation procedure . 11
5.4 Range of approval. 11
6 Electrical tests . 12
6.1 Installation . 12
6.1.1 General . 12
6.1.2 Through connectors and terminations . 13
6.1.3 Branch connectors . 13
6.2 Measurements . 13
6.2.1 General . 13
6.2.2 Electrical resistance measurements . 14
6.2.3 Temperature measurements . 14
6.3 Heat cycling test . 14
6.3.1 General . 14
6.3.2 First heat cycle . 15
6.3.3 Second heat cycle . 15
6.3.4 Subsequent heat cycles . 17
6.4 Short-circuit test for connectors according to Class A . 17
6.4.1 General . 17
6.4.2 Aluminium conductors with cross-sectional areas below 1 000 mm and
copper conductors with cross-sectional areas below 630 mm . 18
6.4.3 Aluminium conductors with cross-sectional areas ≥ 1 000 mm and
copper conductors with cross-sectional areas ≥ 630 mm . 18
6.5 Assessment of results . 19
6.6 Requirements . 19
6.7 Examples of electrical test loop configurations and associated parameters . 19
7 Mechanical test . 25
7.1 General . 25
7.2 Method . 25
7.3 Requirements . 25
8 Test reports . 26
8.1 General . 26
8.2 Electrical tests . 26
8.3 Mechanical test . 26
Annex A (normative) Equalizers and their preparation . 27
A.1 Requirements for equalizers . 27
A.2 Recommendations for welding equalizers . 27
Annex B (normative) Measurements . 29

B.1 Potential measuring positions for typical connectors . 29
B.2 Temperature measurement . 29
B.3 Equivalent conductor resistance . 29
Annex C (informative) Recommendations to decrease uncertainties of measurement . 30
C.1 Handling the test loop . 30
C.2 Measurements, instruments and readings . 30
Annex D (normative) Calculation of adiabatic short-circuit current . 31
Annex E (informative) Determination of the value of the short-circuit current . 32
Annex F (normative) Calculation method . 33
F.1 General . 33
F.2 Measurements made . 33
F.3 Connector resistance factor k . 33
F.4 Initial scatter δ . 34
F.5 Mean scatter β . 34
F.6 Change in resistance factor of each connector . 36
F.6.1 General . 36
F.6.2 Line of best fit .
...