BS EN 50483-4-2009 English
BS EN 50483-4-2009 English
BS EN 50483-4-2009 English
Part 4: Connectorss
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National foreword
This British Standard is the UK implementation of EN 50483-4:2009.
The UK participation in its preparation was entrusted by Technical Committee
GEL/20, Electric cables, to Subcommittee GEL/20/11, Cable accessories.
A list of organizations represented on this committee can be obtained on
request to its secretary.
This publication does not purport to include all the necessary provisions of a
contract. Users are responsible for its correct application.
© BSI 2009
ISBN 978 0 580 56180 1
ICS 29.240.20
ICS 29.240.20
English version
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language made by translation under er the responsibility of a CENELEC member into its own language and notified
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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
© 2009 CENELEC - All rights of exploitation in any form and by any means reserved worldwide for CENELEC members.
Foreword
The text of the draft was submitted to the formal vote and was approved by CENELEC as
EN 50483-4 on 2008-12-01.
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;
– lf suppo
Part 2: Tension and suspension clamps for self supporting system;
– Part 4: Connectors;
__________
BS EN 50483-4:2009
–3– EN 50483-4:2009
Contents
1 Scope ............................................................................................................................... 4
2 Normative references........................................................................................................ 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 m
Figure 1 – Test arrangement .................................................................................................
...........
......... 10
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1 Scope
EN 50483 series applies to overhead line fittings for tensioning, supporting and connecting
aerial bundled cables (ABC) of rated voltage U 0 /U (U m ): 0,6/1 (1,2) kV.
This Part 4 applies to connectors used for the electrical connection of ABC.
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
plies.
ies.
the referenced document (including any amendments) applies. m
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EN 50182:2001, Conductors for overhead lines – Round ire co
concentric lay stranded conductors
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EN 50483 series, Test requirements for low voltage aerial bundled cable accessories
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rovide
ovide by enclosures (IP Code) (IEC 60529:1989)
EN 60529:1991, Degrees of protection provided
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IEC 60050-461, International Electrotechnical Vocabulary (IEV) – Part 461: Electric cables
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]
BS EN 50483-4:2009
–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
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metallic device to connect cable conductors together
[IEV 461-17-03]
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core
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assembly comprising conductor and its own
[IEV 461-04-04, modified]
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3.9
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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
BS EN 50483-4:2009
EN 50483-4:2009 –6–
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
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3.19
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sheath
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shear head
head of a bolt, or a device fitted over
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h of a bolt or a nut, which is designed to break at
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a specified torque
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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
resistivity (Ω.m)
5 Characteristics
These connectors shall connect cables designed to HD 626 and withstand the following type
tests.
6 Marking
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.
discrediting the connector. Tests can be repeated using a new connector and a new cable.
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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.
BS EN 50483-4:2009
EN 50483-4:2009 –8–
8 Type tests
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.
The following tests are designed to ensure that the IPC is both mechanically sound and does
not damage the conductors it connects:
Test Subclause
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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.
BS EN 50483-4:2009
–9– EN 50483-4:2009
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, 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).
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8.1.2.1.3 Procedure
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Connectors shall be installed in accordance w the manufacturer’s instructions.
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When the connector is designed with a shear-head, it shall be tightened to the manufacturer’s
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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:
NOTE Loads for other designs of ABC shall be agreed between the customer and the manufacturer.
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.
8.1.2.2.1 Principle
To ensure that the IPC provides mechanical security of the branch cable.
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.
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NOTE Where other combinations are required these may be agreed
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manufacturer’s instructions.
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1 branch
2 main secured in mechanical device
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.
8.1.2.2.4 Requirements
ut breaking
The cores shall maintain the test load for 60 s without brea or any damage that would
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8.1.2.3.1 Principle
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To ensure that when tightened, the boltsts used
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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.
BS EN 50483-4:2009
EN 50483-4:2009 – 12 –
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
8.1.2.4.1 Principle
To ensure that the shear head mechanism functions correctly within the specified torque range.
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The samples shall be tested in either of the following cross-section combinations:
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Main Branch
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min.
n. min.
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max.
a 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.
BS EN 50483-4:2009
– 13 – EN 50483-4:2009
8.1.2.5.1 Principle
Two connectors shall be installed in the manner for which they are designed.
Main Branch
max. min.
max. max.
NOTE See EN 50483-1, 9.1, for information on the use of a lower temperature.
mperat
perat
the test is carried out at the specified temperature the impact test shall be made immediately.
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BS EN 50483-4:2009
EN 50483-4:2009 – 14 –
Dimensions in millimetres
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1 hammer 900 g 4 steel 10 kg
2 steel intermediate piece 100 g 5 slightly round edges
3 test piece
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.
BS EN 50483-4:2009
– 15 – EN 50483-4:2009
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:
NOTE The choice of the class should be agreed between the manufacturer and the customer.
8.1.3.1.1 Principle
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Main Branch
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min. min.
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max.. min.
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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.
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 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 resistivity of the water used in this test shall be in accordance with EN 50483-1, 9.1.6.
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
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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
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.
Dimensions in millimetres
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1 insulated main conductor 5 mounted connector
2 tank 6 metallic electrode
3 insulated tap conductor 7 metallic balls
4 insulating cap
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.
BS EN 50483-4:2009
EN 50483-4:2009 – 18 –
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.
0483-
483- 9.1.7.
The voltage shall be applied at a speed specified in EN 50483-1,
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1 metallic gauze 3 insulating cap
2 ABC cores 4 connector
8.1.3.1.4 Requirements
This test is required for connectors for which the dielectric test in water is not applicable due to
the connector design.
BS EN 50483-4:2009
– 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.
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
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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.
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Dimensions in millimetres
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8.1.3.2.4 Requirements
8.1.4.1 Principle
To ensure electrical contact is established when the IPC is applied in cold conditions.
BS EN 50483-4:2009
– 21 – EN 50483-4:2009
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.
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Electrical continuity shall be measured between the main
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branch cables.
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The IPC shall be installed in accordance with the manu instructions using a torque
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Alternatively the assembly can be removed vedd from the cold chamber and the torque applied
outside. In this case the temperature off the
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connector and the core shall be monitored and the
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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.
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.
8.1.5.1.1 Principle
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.
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.
es
s of 14 days. This 14-day cycle consists of
Method 1: Combined test. There shall be 4 cycles
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EN 50483-6, 8.4.2.
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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.
BS EN 50483-4:2009
– 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.
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.
8.1.5.2.1 Principle
onditi
nditi
To ensure that the connector is not affected by climatic conditions.
8.1.5.2.3
8.1.5.2.3.1
Procedure
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).
BS EN 50483-4:2009
EN 50483-4:2009 – 24 –
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ORIENTATION 1 ORIENTATION 2
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3 lamp
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Figure 7 – Orientation
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on of the
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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.
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.
BS EN 50483-4:2009
– 25 – EN 50483-4:2009
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.
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.
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.
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Connectors shall be installed in accordance with the manuf
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The same core (e.g. Phase 1) of a cable with the same cross-section shall be used for each
test.
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ctions shall be tested; that is max. max. and min. min.
the maximum and minimum cross-sections
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Where bolted connectors are to be tested, the test installation shall be made as defined in
8.1.1 for IPCs.
8.2.2.1 Principle
The purpose of this test is to ensure that the connector makes an acceptable mechanical
connection to the cable.
8.2.2.3 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:
BS EN 50483-4:2009
EN 50483-4:2009 – 26 –
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 before the initial load, or after releasing the initial
load, and before applying the test load.
ZZZE]I[ZFRP
Z
ZZ
ak
2 2
35 mm
m to 150 mm Aluminium
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Partial tension:
10 % MBL for 60 s
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Phase
Phases:
60 % MBL for 60 s
16 mm² to 150 mm² Aluminium
Neutral messenger system
Neutral:
95 % MBL for 60 s
25 mm² to 95 mm² Aluminium alloy
Dimensions in millimetres
Key
1 fixed point
2 pre-insulated sleeve
8.2.2.4 Requirement
In order to meet the requirements of the type tests at least one of the two dielectrical tests shall
be carried out.
Connector classes:
NOTE The choice of the class should be agreed between the manufacturer and the customer.
8.2.3.1.1 Principle
ection.
on.
Two samples shall be tested of each equal cross-section.
e.
ZZZE]I[ZFRP
ZZ
ak
8.2.3.1.3 Procedure
ab
See 8.1.3.1.3.1.
w
w
60 s according to Figure 9.
NOTE A voltage of 6 kV a.c. may be used when agreed between customer and manufacturer.
BS EN 50483-4:2009
EN 50483-4:2009 – 28 –
Dimensions in millimetres
c om
e.
ZZZE]I[ZFRP
Z
ZZ
ak
Key
ab
1 core 4 water
.b
3 metallic electrode
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Figure 9 – Illustrative
strat set up for dielectrical voltage test
See 8.1.3.1.3.2.
The test arrangement, as shown in Figures 4 or 5, shall be used where the pre-insulated
through connector replaces the IPC.
8.2.3.2 Requirements
8.2.4.1 Principle
8.2.4.3 Procedure
The connectors, conductor and tools 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 See EN 50483-1, 9.1, for information on the use of a lower temperature.
At least 3 h at ambient temperature after having been removed from the cold chamber, the
sleeves shall be subjected to
8.2.4.4 Requirements
8.2.5.1.1 Principle
w
8.2.5.1.3 Procedure
8.2.5.1.4 Requirements
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.
In order to meet the requirements of the type tests at least one of the two climatic ageing tests
(as detailed in EN 50483-6, 8.5) shall be completed. The choice of the test shall be agreed
between the manufacturer and the customer.
8.2.5.2.1 Principle
8.2.5.2.3 Procedure
ane. These
horizontal plane and the lamp in a vertical plane. Th two planes shall intersect in the middle
ab
amples
of the lamp and in the middle of the samples.mples The main core shall be orthogonal in the
described vertical plane (see Figure 10)..
.b
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BS EN 50483-4:2009
– 31 – EN 50483-4:2009
m
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e.
Key
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2 lamp 5 core
.b
3 top view
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Figure 10 – Climatic
Clim
Clima ageing test arrangement
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8.2.5.2.3.2 es - Method 2
Climatic ageing test
8.2.5.2.4 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 following tests shall be carried out.
The Class 1 and Class 2 sleeves shall meet the requirements of the dielectrical voltage test in
air, 8.2.3.1.3.2.
For Class 1 sleeves, the assembly formed by the connector and the cores shall then be taken
out of the metallic balls, without any mechanical stress, and shall meet the requirements of the
dielectrical voltage test in water given in 8.2.3.1.3.1 but with a voltage of 1 kV a.c.
BS EN 50483-4:2009
EN 50483-4:2009 – 32 –
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.
8.2.7.1 Principle
The purpose of this test is to ensure an acceptable dielectrical and mechanical behaviour when
heat cycles and mechanical load are combined.
When pre-insulated sleeves have the same external diameter, only maximum and minimum
cross-sections of the same type of conductor are tested.
Mechanical loads shall be applied to the extremities of the stripped cores using appropriate
tensioning equipment.
Thermocouples shall be placed on the central conductive part of the two sleeves located at
either end of the test assembly.
The reference temperature shall be measured in the middle of a stripped core of (1,0 ± 0,1) m
and located not less than 1 m from any supporting or connecting components.
8.2.7.3 Procedure
The load, for the appropriate type of system, shall be applied to the extremities of the core and
varied as required throughout the test.
Thermal cycles, with duration of 90 min, shall be applied to the test assembly.
For the first 45 min of every cycle, current flowing through the test assembly shall create the
temperature rise.
BS EN 50483-4:2009
– 33 – EN 50483-4:2009
The reference temperature of the conductor shall be maintained at the normal operating
temperature within an interval of ± 3 K as shown in Annex C of EN 50483-1. This temperature
shall be reached within 5 min to 15 min at the beginning of the cycle.
For the last 45 min, of each cycle, the test assembly shall be cooled to (25 ± 3) °C. The
temperature shall then be maintained, at this value, until the end of the cycle.
At 24 h intervals, at the end of the normal operating temperature heating period, the
temperatures reached by the two sleeves shall be recorded.
8.2.7.3.1 Test arrangement and procedure for phase conductors of neutral messenger
system and self supporting systems
Figure 11 shows a typical test arrangement. The test configuration can differ from this
arrangement as long as it complies with the phase conductor lengths.
m
co
k e.
ba
a
.b
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Key
1 phase conductor tensioning equipment
test sleeve
8.2.7.3.1.2 Procedure
The variation in mechanical load and temperature is shown, diagrammatically, in Figure 12.
m
co
k e.
ba
a
.b
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Key
1 normal operating temperature 7 45 min
2 mechanical load variation 8 90 min basic cycle
3 conductor temperature
4 10 min X time axis
5 24 h Y1 mechanical load axis
6 45 min Y2 temperature axis
A tensile load shall be applied until a value equal to 35 % of the MBL of the cable is reached.
This value shall be achieved in approximately 60 s.
The load shall then be maintained for 10 min using a manual or automatic continuous
adjustment. The assembly shall be left to self stabilize mechanically for 24 h without any
adjustment.
Once the assembly has stabilized the thermal cycles shall be started. At the end of the first
cycle, the tensile load shall be set at 20 % of MBL of the cable.
At least once every 24 h, the tensile load shall be adjusted to 20 % of the MBL of the cable.
The test arrangement is shown in Figure 11 where the phase conductor shall be replaced with
the neutral conductor.
8.2.7.3.2.2 Procedure
wn,
n, dia
The variation in mechanical load and temperature is shown, diagrammatically, in Figure 13.
m
co
5 s and 60 s inclusive.
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BS EN 50483-4:2009
EN 50483-4:2009 – 36 –
m
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e.
k
a ba
.b
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Key
1 normal operating temperature 6 one cycle = 90 min
2 mechanical cycle
3 thermal cycle X time axis
4 45 min Y1 mechanical load axis
5 75 min Y2 temperature axis
Tensile loads
F1 F2
8.2.7.4 Requirements
At the end of the heating period, the sleeves’ temperatures shall be lower than the temperature
of the reference core.
The Class 1 and Class 2 sleeves shall meet the requirements of the dielectrical voltage test in
air, 8.2.3.1.3.2.
For Class 1 sleeves 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, 8.2.3.1.3.1 but with a voltage of 1 kV.
The four sleeves shall meet the requirements of the mechanical test in 8.2.2.
The same core (e.g. Phase 1) of a cable with the same cross-section shall be used for each
test.
orr neutral
The mechanical loads given below are applicable for neut messenger and self-supporting
ABC systems.
imum and
Where bolted lugs are to be tested the maximum a minimum cross-sections, for which the
lug is designed, shall be used.
tallation
llation shall be as defined in 8.1.1 for IPCs.
The torque used to make the test installation
8.3.2.1 Principle
The purpose of this test is to ensure that the lug makes an acceptable mechanical connection
to the cable.
8.3.2.3 Procedure
The assembly shall be subjected to a tensile load, applied to the conductor, in accordance with
Figure 14.
The initial load shall be 10 % of the MBL of the conductor for which it is designed, or 1 500 N,
whichever is less. The rate of load increase shall be in accordance with EN 50483-1, 9.1.4.
The cable shall be marked at the point at which it leaves the lug.
BS EN 50483-4:2009
EN 50483-4:2009 – 38 –
Dimensions in millimetres
c om
e.
ak
Key
ab
1 pre-insulated lug
.b
2 fixed point
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Figure 14 – Illustrative
trative
ative installation of the mechanical test
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8.3.2.4 Requirements
This test applies only to terminal lugs having a palm in aluminium or in aluminium alloy.
8.3.3.1 Principle
To ensure that water cannot migrate through the lug to the ABC.
The lug shall be installed on to the cable in accordance with the manufacturer’s instructions.
The assembled lug and cable shall be placed in a tank and covered with water to a depth of
+ 100
(300 −0 ) mm measured above the lug.
BS EN 50483-4:2009
– 39 – EN 50483-4:2009
The core shall pass out of the tank, through an appropriate seal, which shall be designed to
prevent any excessive stress on the insulation.
Dimensions in millimetres
m
co
e.
ak
Key
1 water
ab
2 lug
.b
3 seal
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Figure 15
5 – Illus
Illustrative figure of immersed lug
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8.3.3.3 Procedure
8.3.3.4 Requirements
Where a pre-insulated sleeve has the same design as the barrel of the pre-insulated lug this
test is not required if the pre-insulated sleeve has met the requirements of 8.2.4.
8.3.4.1 Principle
8.3.4.3 Procedure
The lugs, conductor and tools 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 See EN 50483-1, 9.1, for information on the use of a lower temperature.
At least 3 h at ambient temperature after having been removed from the cold chamber, the lugs
shall be subjected to the mechanical testing as detailed in 8.3.2.
8.3.4.4 Requirements
8.3.5.1.1 Principle
n 8.3.3.
See test arrangement of water tightness test given in .3.3.
e.
8.3.5.1.3 Procedure
ak
ype
e tes
In order to meet the requirements of the type test
tests at least one of the two climatic ageing tests
ab
tomer.
mer.
between the manufacturer and the customer.
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NOTE The temperature may be less 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 as in Figure 10 where the pre-insulated sleeve is replaced by the lug.
The sample shall be installed in the orientation shown in Figure 10 where the pre-insulated
sleeve is replaced by the lug.
8.3.5.1.4 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 lugs shall meet the requirements of the water tightness test (8.3.3)
after an immersion time of 12 h.
BS EN 50483-4:2009
– 41 – EN 50483-4:2009
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.
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) shall be performed where applicable.
8.3.5.2.1 Principle
8.3.5.2.3 Procedure m
6, 8.4.
The procedure shall be in accordance with EN 50483-6,
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e.
8.3.5.2.4 Requirements
ak
No deterioration of the connectors shallll occur which would impair their normal function.
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8.3.5.3 n test
Bi-metallic corrosion est in
i sodium hydroxide (NaOH) solution
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8.3.5.3.1 Principle
To ensure that when exposed to a corrosive environment corrosion of the copper palm does
not affect the aluminium part of the connector or the ABC.
The lug shall be installed onto the cable in accordance with the manufacturer’s instructions.
The assembled lug and cable shall be placed in a tank and covered with a normal sodium
+ 100
hydroxide solution (40 g/l of water) to a depth of (300 −0 ) mm measured above the lug.
The end of the insulated core shall be brought out of the tank clear of the sodium hydroxide
solution.
BS EN 50483-4:2009
EN 50483-4:2009 – 42 –
Dimensions in millimetres
Key
m
co
1 ABC core 3 lug
2 sodium hydroxide solution 4 ccopper part
e.
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8.3.5.3.3 Procedure
.b
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or 24 h.
The assembly shall be immersed for
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8.3.5.3.4 Requirements
After removing the insulation of the lug, no traces of corrosion shall be observed on the
aluminium parts.
Annex A
(informative)
A.1 Principle
To ensure that the IPC is suitable when used with conductors carrying current and short-circuit
current.
The connectors should be tightened to the minimum torques specified by the manufacturer.
herm
Each pin should be fitted with a thermocouple close to the locking system.
Distances between each connector and power source should be a minimum of 1 m length.
Preparation of cables and core before tests, installation of the connectors and method of
temperature measurement on connectors, should be carried out in accordance with
EN 50483-5, 5.3.2, EN 50483-5, 5.3.3 and EN 50483-5, 5.4.1.
BS EN 50483-4:2009
EN 50483-4:2009 – 44 –
m
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ak
Key
1 ore)
e)
insulated conductor (copper or aluminium core)
ab
2 pin
.b
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Figure A.1
1 – Exa
Example of a pin connection
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BS EN 50483-4:2009
– 45 – EN 50483-4:2009
m
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ab
.b
Key
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A.3 Procedure
An a.c. current for which the connector is designed should be applied until temperature
stabilization of the different mounted elements is achieved.
Temperature stabilization should be considered to have been achieved when the temperature
of each connector does not fluctuate by more than 2 K for 15 min.
Temperature T 1 of each connector and temperature T 2 of each pin linked to the connector
should be recorded as well as the ambient temperature T 0 .
BS EN 50483-4:2009
EN 50483-4:2009 – 46 –
The over-current value should be calculated with a current density of approximately 160 A/mm²
for bare copper braid.
To enable a close approximation to the specified over-current value, the duration of the over-
current, nominally 1 s, can be adjusted within a range of 0,85 s up to 1,15 s observing the
relationship I 2 ⋅t = Constant.
After each over-current, the loop should be allowed to cool down to a temperature ≤ 35 °C.
After this over-current series, the a.c. current, as used before, should be applied once more to
the assembly until temperature stabilization, of the different mounting elements, is achieved.
Temperature stabilization should be considered to have beenee achieved when the temperature
of each connector does not fluctuate by more than 2 K forr 15 m
min.
m
co
A.3.4 Requirement
ab
erify
ify both
Each connector and each pin should verify bot
bo conditions:
.b
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(T 3 – T 5 ) – (T 1 – T 0 ) < 10 K
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(T 4 – T 5 ) – (T 2 – T 0 ) < 10 K
BS EN 50483-4:2009
– 47 – EN 50483-4:2009
Bibliography
EN 61284, Overhead lines – Requirements and tests for fittings (IEC 61284)
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