http//:www.wangd.com 最专业的电气网站 ANSI C119.1-2006 American National Standard for Electric Connectors— Sealed Insulated Underground Connector Systems Rated 600 Volts http//:www.wangd.com 最专业的电气网站 http//:www.wangd.com 最专业的电气网站 ANSI C119.1-2006 American National Standard For Electric Connectors— Sealed Insulated Underground Connector Systems Rated 600 Volts Secretariat: National Electrical Manufacturers Association Approved January 13, 2006 American National Standards Institute, Inc. ANSI C119.1-2006 http//:www.wangd.com 最专业的电气网站 NOTICE AND DISCLAIMER The information in this publication was considered technically sound by the consensus of persons engaged in the development and approval of the document at the time it was developed. Consensus does not necessarily mean that there is unanimous agreement among every person participating in the development of this document. NEMA standards and guideline publications, of which the document contained herein is one, are developed through a voluntary consensus standards development process. This process brings together volunteers and/or seeks out the views of persons who have an interest in the topic covered by this publication. While NEMA administers the process and establishes rules to promote fairness in the development of consensus, it does not write the document and it does not independently test, evaluate, or verify the accuracy or completeness of any information or the soundness of any judgments contained in its standards and guideline publications. NEMA disclaims liability for any personal injury, property, or other damages of any nature whatsoever, whether special, indirect, consequential, or compensatory, directly or indirectly resulting from the publication, use of, application, or reliance on this document. 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Any certification or other statement of compliance with any health or safety–related information in this document shall not be attributable to NEMA and is solely the responsibility of the certifier or maker of the statement. http//:www.wangd.com 最专业的电气网站 ANSI C119.1-2006 of an American National Standard requires verification by AMERICAN Approval ANSI that the requirements for due process, consensus, and other NATIONAL criteria for approval have been met by the standards developer. is established when, in the judgment of the ANSI Board of STANDARD Consensus Standards Review, substantial agreement has been reached by directly and materially affected interests. Substantial agreement means much more than a simple majority, but not necessarily unanimity. Consensus requires that all views and objections be considered, and that a concerted effort be made toward their resolution. The use of American National Standards is completely voluntary; their existence does not in any respect preclude anyone, whether he has approved the standards or not, from manufacturing, marketing, purchasing, or using products, processes, or procedures not conforming to the standards. The American National Standards Institute does not develop standards and will in no circumstances give an interpretation of any American National Standard. Moreover, no person shall have the right or authority to issue an interpretation of an American National Standard in the name of the American National Standards Institute. Requests for interpretations should be addressed to the secretariat or sponsor whose name appears on the title page of this standard. Caution Notice: This American National Standard may be revised or withdrawn at any time. The procedures of the American National Standards Institute require that action be taken periodically to reaffirm, revise, or withdraw this standard. Purchasers of American National Standards may receive current information on all standards by calling or writing the American National Standards Institute. Published by: National Electrical Manufacturers Association 1300 North 17th Street, Rosslyn, VA 22209 Copyright 2006 by National Electrical Manufacturers Association All rights reserved including translation into other languages, reserved under the Universal Copyright Convention, the Berne Convention for the Protection of Literary and Artistic Works, and the International and Pan American Copyright Conventions. No part of this publication may be reproduced in any form, in an electronic retrieval system or otherwise, without the prior written permission of the publisher. Printed in the United States of America. i ANSI C119.1-2006 http//:www.wangd.com 最专业的电气网站 This page intentionally left blank. ii http//:www.wangd.com 最专业的电气网站 ANSI C119.1-2006 Contents Page Foreword 1 ........................................................................................................................ vii Scope and Purpose .......................................................................................................1 1.1 Scope .............................................................................................................1 1.2 Purpose.............................................................................................................1 2 Referenced American National Standard ......................................................................1 3 Definitions 4 Test Conditions ..............................................................................................................2 5 .............................................................................................................1 4.1 General .............................................................................................................2 4.2 Current cycle .....................................................................................................2 4.3 Mechanical tests ...............................................................................................2 4.4 Thermal stability test .........................................................................................2 4.5 Integrity of seal and connector insulation test...................................................2 Performance...................................................................................................................2 5.1 General .............................................................................................................2 5.2 Resistance ........................................................................................................3 5.3 5.4 5.5 5.6 5.2.1 CCT resistance ....................................................................................3 5.2.2 CCST resistance..................................................................................3 Temperature......................................................................................................3 5.3.1 CCT temperature .................................................................................3 5.3.2 CCST temperature...............................................................................3 5.3.3 Stability determination for CCT and CCST………………………………3 Mechanical tests ...............................................................................................3 5.4.1 Tensile strength ...................................................................................3 5.4.2 Rated conductor strength ....................................................................3 5.4.3 Tension ................................................................................................3 Thermal performance of insulated system under load (ISUL)..........................4 5.5.1 Performance requirements for ISUL ....................................................4 5.5.2 Stability determination for ISUL ...........................................................4 5.5.3 Insulation..............................................................................................5 Integrity of seal and connector insulation .........................................................5 5.6.1 Insulation resistance ............................................................................5 5.6.2 Dielectric withstand ..............................................................................5 5.6.3 Leakage current ...................................................................................5 iii ANSI C119.1-2006 http//:www.wangd.com 最专业的电气网站 6 Test Procedures, General..............................................................................................5 6.1 6.2 7 6.1.1 Description ...........................................................................................5 6.1.2 Family sample set ................................................................................5 Test assembly methods ....................................................................................5 6.2.1 Installation details ................................................................................5 6.2.2 Conductor preparation for electrical tests............................................5 6.2.3 Conductor preparation for mechanical tests........................................6 6.2.4 Connector preparation .........................................................................6 6.2.5 Connector installation ..........................................................................6 Current Cycling in Air .....................................................................................................6 7.1 7.2 Test assembly ...................................................................................................6 7.1.1 Conductors...........................................................................................6 7.1.2 Connectors...........................................................................................6 7.1.3 Equalizers ............................................................................................6 7.1.4 Conductor lengths................................................................................6 7.1.5 Control conductor.................................................................................7 7.1.6 Equivalent aluminum/copper conductors.............................................7 7.1.7 Multiple control conductors ..................................................................7 Loop configuration and location........................................................................8 7.2.1 CCT method.........................................................................................8 7.2.2 CCST method ......................................................................................8 7.3 Ambient conditions..........................................................................................10 7.4 Test current .....................................................................................................10 7.5 Temperature conditions ..................................................................................10 7.6 7.7 iv Test connectors ................................................................................................5 7.5.1 CCT temperature conditions..............................................................10 7.5.2 CCST temperature conditions ...........................................................10 Current cycle periods ......................................................................................10 7.6.1 Current cycle-ON period ....................................................................10 7.6.2 CCT current cycle-OFF period...........................................................11 7.6.3 CCST current cycle-OFF period ........................................................11 Measurements ................................................................................................11 7.7.1 Resistance measurements ................................................................12 7.7.2 Temperature measurements .............................................................12 7.8 Maximum number of current cycles................................................................12 7.9 Evaluation interval...........................................................................................12 http//:www.wangd.com 最专业的电气网站 8 7.9.1 Evaluation by the CCT method ..........................................................12 7.9.2 Evaluation by the CCST method .......................................................13 Tensile Strength ...........................................................................................................13 8.1 Test connectors ..............................................................................................13 8.1.1 8.2 9 ANSI C119.1-2006 Number of samples............................................................................13 Pullout test ......................................................................................................13 Thermal Stability of insulated system under load (ISUL).............................................13 9.1 Test assembly .................................................................................................13 9.2 Test conditions ................................................................................................13 9.3 Test current .....................................................................................................14 9.4 Measurements ................................................................................................14 10 Integrity of Seal and Connector Insulation...................................................................14 10.1 Assemblies for test..........................................................................................14 10.2 Procedural sequence ......................................................................................14 10.3 Water immersion for twenty-four (24) hours ...................................................14 10.4 Insulation resistance measurement ................................................................15 10.5 Dielectric withstand test ..................................................................................15 10.6 Heat conditioning ............................................................................................15 10.7 Flex .................................................................................................................15 10.8 Twist ................................................................................................................15 10.9 Cold conditioning ............................................................................................15 10.10 Current cycle and water submersion ..............................................................15 10.11 Leakage current test .......................................................................................16 11 Test Report ..................................................................................................................16 12 Marking ........................................................................................................................16 12.1 Connector system marking .............................................................................16 12.2 Assembly instructions .....................................................................................16 Figures 1 An example of a vertical test configuration …………………………………………………8 2 Flexing and Twisting ....................................................................................................17 v ANSI C119.1-2006 http//:www.wangd.com 最专业的电气网站 Tables 1 Test duration ..................................................................................................................2 2 Tensile load, AWG cable ...............................................................................................4 3 Tensile load, metric cable ..............................................................................................4 4 Conductor lengths for current cycle test, AWG sizes ....................................................7 5 Conductor lengths for current cycle tests, metric sizes .................................................7 6 Suggested initial test current to raise AWG control conductor temperature 100°C ......9 7 Suggested initial test current to raise metric control conductor temperature 100°C .....9 8 Minimum current cycle periods for AWG control conductors ......................................10 9 Minimum current cycle periods for metric control conductors .....................................11 10 Resistance and temperature measurement intervals ..................................................11 Annexes (Informative) vi A Optional Tests to Meet the Requirements of UL 486D................................................18 B Standards which are Applicable to C119.1 by Inference, but Not Directly Referenced in the Standard ...............................................................19 C Test Loop Diagrams.....................................................................................................20 D Suggested Thermocouple Locations ...........................................................................22 E Guarded Circuit ............................................................................................................24 http//:www.wangd.com 最专业的电气网站 ANSI C119.1-2006 Foreword (Neither this foreword nor any of the informative annexes is a part of American National Standard C119.1-2006.) The standard covers electrical, mechanical, and sealing requirements of connectors rated 600 volts and installed underground. This standard was initially developed by an EEI-NEMA Joint Committee on Underground Distribution Connectors and Connector Systems and published by the American National Standards Institute in 1974. Suggestions for improvement of this standard will be welcome. They should be sent to: National Electrical Manufacturers Association 1300 North 17th Street, Suite 1752 Rosslyn, VA 22209 This standard was processed and approved for submittal to ANSI by the Accredited Standards Committee on Connectors for Electrical Utility Applications, C119. Committee approval of this standard does not necessarily imply that all committee members voted for its approval. At the time it approved this standard, the ANSI ASC C119 Committee had the following members: Douglas Harms, Chairman Ronald Lai, Vice Chairman Vince Baclawski, Secretary Organization Represented: Name of Representative: Aluminum Association Jean-Marie Asselin Electric Utility Industry Warren Hadley Douglas Harms James Harris Harry Hayes Curt Schultz James Sprecher Gerald Wasielewski David West National Electric Energy Testing, Research & Application Center Thomas Champion National Electric Manufacturers Association David Dembowski Pierre Guyot Barry Johnson Ronald Lai Frank Muench Greg Nienaber Frank Stepniak Carl Tamm Carl Taylor David Thompson Allen Wilcox James Zahnen Rural Utilities Service (RUS) Trung Hiu vii ANSI C119.1-2006 http//:www.wangd.com 最专业的电气网站 Tennessee Valley Authority Jeffrey Nelson Underwriters Laboratories, Inc. Jake Killinger Other Peter Bowers Stanley Hodgin The C119.1 Subcommittee on Sealed Underground Connector Systems, which developed the revisions of this standard, had the following members: James Zahnen, Chairman David West, Vice Chairman Vince Baclawski, Secretary Mike Ferretti Pierre Guyot Warren C. Hadley Douglas P. Harms Trung Hiu Barry Johnson Jake Killinger Ronald Lai Thomas McKoon Richard Morin Greg T. Nienaber Walter Romanko Curt Schultz James D. Sprecher Carl R. Tamm Carl Taylor Richard (Jeff) J. Waidelich Gerald Wasielewski David West Allen Wilcox James Zahnen viii http//:www.wangd.com 最专业的电气网站 AMERICAN NATIONAL STANDARD ANSI C119.1-2006 For Electric Connectors— Sealed Insulated Underground Connector Systems Rated 600 Volts 1 Scope and Purpose 1.1 Scope This standard covers sealed, insulated underground connector systems rated at six hundred (600) volts for utility applications and establishes electrical, mechanical, and sealing requirements for sealed underground connector systems. 1.2 Purpose The purpose of this standard is to give reasonable assurance to the user that sealed, insulated underground connector systems meeting the requirements of this standard will perform in a satisfactory manner, provided they have been properly selected for the intended application and are installed in accordance with the manufacturer’s recommendations. 2 Referenced American National Standard This standard is intended to be used in conjunction with the following standards. When this referenced standard is superseded by a revision approved by the American National Standards Institute, the referenced revision shall apply. Standards that are referenced by inference are shown in Annex B ASTM E4-89 Practices for Load Verification of Testing Machines IEEE 837-2002 Qualifying Permanent Connections used in Substation Grounding 3 Definitions CCST: Current Cycle Submersion Test where current cycle heating is done in air and cooling is done using water submersion. CCT: Current Cycle Test where current cycle heating and cooling are done in air. connector: A device that joins two or more conductors for the purpose of providing a continuous electrical path. connector assembly: The connector system installed on the conductor(s). connector system: A connector and its associated insulating and sealing components. control cable: A conductor of the same type and size as the conductor in the current cycle loop that would be at the highest temperature. guarded circuit: A circuit used to eliminate or to minimize the current flow between the insulation and conductor ends, caused by surface leakage currents. input conductor: Supply side of the connector assembly. 1 ANSI C119.1-2006 http//:www.wangd.com 最专业的电气网站 ISUL: Insulation System Under Load conditions. output conductor: Load side of the connector assembly. seal: An interface preventing the ingress of moisture and foreign matter into the connector assembly. underground: Below grade application, including direct burial. 4 Test Conditions Connectors shall be installed and tested for current carrying, mechanical, and sealing performance in accordance with the conditions noted in 6.0 through 10.0. 4.1 General The connector system shall meet the performance requirements specified in 5.0. 4.2 Current cycle The connector shall be tested in accordance with 7.0 on bare conductors for the number of test cycles in Table 1, depending on the choice of test method. Table 1 – Test Duration Connector Class Heavy Duty (Class A) Number of Test Cycles for: CCT Method CCST Method 500 100 NOTE—The connector classification defines the severity of the heat aging test. Exception: Copper-bodied connectors, for use with copper cable only, do not require current cycling in air. This exception is provided since copper-bodied connectors, in conjunction with copper cable, do not exhibit high thermal expansion and creep characteristics. NOTE—This test is run on bare conductor to provide repeatability of test results. 4.3 Mechanical tests Tests of the tensile strength of the connector shall be conducted in accordance with 8.0. 4.4 Thermal stability test The thermal performance of the connector system shall be tested in accordance with 9.0. 4.5 Integrity of seal and connector insulation test The integrity of the connector system seal and insulation shall be tested in accordance with 10.0. 5 Performance 5.1 General Connectors shall conform to the appropriate performance requirements in 5.0 when installed and tested in accordance with the methods specified in 7.0 through 10.0. 2 http//:www.wangd.com 最专业的电气网站 5.2 ANSI C119.1-2006 Resistance The resistance of the connection tested in accordance with 7.0 shall be stable. Stability is achieved if any resistance measurement, including allowance for measurement error, does not vary by more than plus or minus five percent (+/-5%) from the average of all the measurements at specified intervals during the course of the test. 5.2.1 CCT resistance The resistance of the connection tested by the Current Cycle Test method in accordance with 7.0 shall be stable between the twenty-fifth (25th) cycle and the completion of the number of current cycles required in 4.2. 5.2.2 CCST resistance The resistance of the connection tested by the Current Cycle Submersion Test method in accordance with 7.0, shall be stable between the tenth (10th) cycle and the completion of the number of current cycles required in 4.2. 5.3 Temperature The temperature of the connector tested in accordance with 7.0 shall not exceed the temperature of the control conductor. The temperature difference between the control conductor and the connector shall be stable. 5.3.1 CCT temperature The temperature of the connector tested by the Current Cycle Test method shall be stable between the twenty-fifth (25th) cycle and the completion of the test. 5.3.2 CCST temperature The temperature of the connector tested by the Current Cycle Submersion Test method shall be stable between the tenth (10th) cycle and the completion of the test. 5.3.3 Stability determination for CCT and CCST Temperature stability for the CCT and CCST tests is achieved if any temperature difference between the control conductor and the connector, including allowance for measurement error, is not more than 10°C below the average of all temperature differences in the respective intervals defined in 5.3.1 and 5.3.2. 5.4 Mechanical tests 5.4.1 Tensile strength The tensile strength of the connections tested in accordance with 8.0 shall be equal to or greater than the values listed in 5.4.3. 5.4.2 Rated conductor strength Rated conductor strength, as used in this standard, shall be determined in accordance with the applicable ASTM standard listed in Annex B, or as furnished by the conductor manufacturer for nonstandard conductors. 5.4.3 Tension The tensile strength of the connector shall be equal to or greater than five percent (5%) of the rated conductor strength of the weaker of the conductors being joined, but not less than the values in Table 2 or Table 3. 3 ANSI C119.1-2006 http//:www.wangd.com 最专业的电气网站 Table 2 – Tensile load, AWG Cable Cable Size AWG 16 14 12 10 8 6 4 3 2 1 Pullout Copper N 133 222 311 356 400 445 623 712 801 890 lbf 30 50 70 80 90 100 140 160 180 200 N Aluminum lbf 200 222 311 356 400 445 45 50 70 80 90 100 Table 3 – Tensile load, metric cable Cable Size 2 mm 1.5 2.5 4 6 10 16 25 35 Pullout Copper N 180 270 330 380 420 540 670 850 lbf* 40 60 75 85 95 120 150 190 Aluminum N lbf* 214 267 334 423 48 60 75 95 *For reference only NOTE—These tables are to ensure mechanical performance for smaller wire sizes where the five percent (5%) minimum is not adequate for long-term reliability. 5.5 Thermal performance of insulated system under load (ISUL) 5.5.1 Performance requirements for ISUL Connectors shall be tested in accordance with 9.0 for one hundred twenty (120) hours and shall remain stable between the seventy second (72nd) hour and the one hundred twentieth (120th) hour of test. The connector temperature shall not exceed the conductor temperature by more than 10°C throughout the entire test. 5.5.2 Stability determination for ISUL Stability is achieved if the change in connector temperature reading does not differ by more than 2°C from the change in input conductor temperature as measured in 9.0. 4 http//:www.wangd.com 最专业的电气网站 5.5.3 ANSI C119.1-2006 Insulation The insulation provided as part of the connector system shall show no visible evidence of deterioration when thermal stability is reached. 5.6 Integrity of seal and connector insulation When tested in accordance with 10.0, this test determines the connector system's ability to withstand repeated handling during underground installation. 5.6.1 Insulation resistance When tested in accordance with 10.2(2), the connector assemblies shall have an insulation resistance greater than six (6) megohms. The insulation resistance of the assemblies measured in 10.2(8), (13), and (15) shall be either: a) greater than ninety percent (90%) of the value measured in 10.2(2) for resistances less than 1x103 megohms or b) a minimum of 1x103 megohms for all other conditions. The latter criterion applies because of the extremely high resistance values and the difficulty in accurately reading analog meters at high resistance levels. 5.6.2 Dielectric withstand The assemblies shall withstand the dielectric withstand tests specified in 10.2(3) and (16) without breakdown. 5.6.3 Leakage current The leakage current of the assemblies shall not exceed 1 milliampere when tested in accordance with 10.2(17). 6 Test Procedures, General 6.1 Test connectors 6.1.1 Description A complete description of the test connectors, conductors, and inhibiting compound shall be included in the test report. 6.1.2 Family sample set To qualify a family of connectors (group of connectors using similar design criteria), a minimum of three (3) sizes (largest, smallest and intermediate) shall be tested. 6.2 Test assembly methods 6.2.1 Installation details All installation details, including methods and tools, not specifically defined or required in 6.0 through 10.0, shall be completely described in the test report. 6.2.2 Conductor preparation for electrical tests The outer surface of the conductors in the contact area shall be mechanically cleaned using a wire brush until the entire contact area of the conductor is clean. 5 ANSI C119.1-2006 http//:www.wangd.com 最专业的电气网站 6.2.3 Conductor preparation for mechanical tests The portion of the conductor that is to be inserted into the connector shall be wiped with a cloth coated with particle-free petroleum jelly. NOTE—This is to increase the severity of all mechanical tests. If the connector is supplied with an inhibiting compound in the wireway, then no conductor preparation is required on the portion of the conductor to be inserted into the connector. 6.2.4 Connector preparation Connectors shall be prepared in accordance with the manufacturer's recommendations. 6.2.5 Connector installation The methods and tools used to install the connector shall be in accordance with the manufacturer's instructions. 7 Current Cycling in Air 7.1 Test assembly (Refer to Figure 1 and to Annex C, Figure C.1 for suggested test loop diagrams.) 7.1.1 Conductors Each connector shall be tested with the combination of input and output bare conductors, representing in number, size, and arrangement the most severe heating condition for which the connector is designed. The connectors shall be installed in their "as received" condition, which may include insulation. The connector may be tested with or without the seals; the choice shall be stated in the test report. If the connector is recommended for use between aluminum-to-aluminum and aluminum-to-copper conductors, it shall be tested on both combinations. 7.1.2 Connectors Four connectors of the same size and type are required for each combination of conductors, as determined in 7.1.1. 7.1.3 Equalizers To provide equipotential planes for resistance measurements and to prevent the influence of one connector on another, equalizers shall be installed in stranded conductor on each side of each connector in the current cycle loop. Equalizers are not required on solid conductors. Any form of equalizer that ensures permanent contact among all the conductor strands for the test duration may be used. 7.1.3.1 Welded equalizers A welded equalizer made from aluminum is recommended for aluminum conductors. 7.1.3.2 Compression sleeve equalizers When the connectors to be tested are identical, a continuous piece of conductor may be used between the connectors, with an equalizer in the center. If a compression sleeve is employed as an equalizer with aluminum conductors, the conductor in the contact area of the equalizer should be prepared as in 6.2.2. 7.1.4 Conductor lengths The exposed length of stranded conductor between the connector and the equalizer, or between the connectors of solid conductors in the current cycle loop, shall be in accordance with Tables 4 and 5. The conductor length in Tables 4 and 5 does not include the length within the connector or equalizer. In 6 ANSI C119.1-2006 http//:www.wangd.com 最专业的电气网站 addition, where connector design permits, the conductor end shall project 12.7 mm (1/2 in.) beyond the connector contact groove. The equalizers at each end of the current cycle loop shall be joined to the power source with additional lengths of the test conductor to be not less than the lengths specified in Tables 4 and 5. Table 4 – Conductor lengths for current cycle tests, AWG sizes Conductor Type Aluminum Exposed length Copper Stranded Solid m in. m in. 4/0 AND Below 2/0 and Below 0.3 12 0.6 24 Over 4/0 Through 750 kcmil Over 2/0 through 500 kcmil 0.6 24 1.2 48 Over 750 kcmil Over 500 kcmil 0.9 36 1.8 72 Table 5 – Conductor lengths for current cycle tests, metric sizes Conductor Type Aluminum Exposed length Copper Stranded Solid m in.* m in.* 120 mm2 and Below 70 mm2 and Below 0.3 12 0.6 24 Over 120 mm2 through 380 mm2 Over 70 mm2 through 240 mm2 0.6 24 1.2 48 Over 380 mm2 Over 240 mm2 0.9 36 1.8 72 *For reference only 7.1.5 Control conductor A control conductor, for determining test current, shall be installed in the current cycle loop (between two equalizers for stranded conductors). The control conductor shall be the same type and size as the conductor in the current cycle loop that will be at the highest temperature. The length of the control conductor shall be twice that given in Tables 4 and 5. 7.1.6 Equivalent aluminum/copper conductors At the manufacturer's option, the size of the control conductor may be determined by selecting from Table 6 or 7 the conductor in the current cycle loop that has the least test current for equivalent aluminum/copper conductors. 7.1.7 Multiple control conductors If the test loop includes different conductors, and a question arises as to which conductor causes the highest temperature rise, a control conductor of each type is required. The test current shall cause the higher temperature rise in one of the control conductors to meet the requirements of 7.5. 7 ANSI C119.1-2006 http//:www.wangd.com 最专业的电气网站 7.2 Loop configuration and location 7.2.1 CCT method The current cycle loop may be of any shape provided the location of thermocouples for the connectors and the center of the control conductor are installed at the same elevation, with at least 203 mm (8 in.) separation between conductors and located at least 305 mm (12 in.) from any exterior wall and at least 610 mm (24 in.) from the floor and the ceiling. An example of a vertical test configuration is shown in Figure 1. Figure 1 – An example of a vertical test configuration 7.2.2 CCST method The control conductor shall be installed on the same horizontal plane as the test connectors. During the current-ON period, no part of the circuit shall be less than 200 mm (8 in.) above the surface of the chilled water. At the beginning of the current-OFF period, the connectors and the control conductor shall be submerged to a minimum of 100 mm (4 in.) below the water surface. 8 ANSI C119.1-2006 http//:www.wangd.com 最专业的电气网站 Table 6 – Suggested initial test current to raise AWG control conductor temperature 100°C Aluminum Copper Conductor Current Conductor Current (AWG) (Amperes) (AWG) (Amperes) 6 90 8 95 4 125 6 130 2 170 4 180 1 200 2 245 1/0 230 1/0 340 2/0 270 2/0 400 3/0 320 3/0 470 4/0 380 4/0 550 250 kcmil 410 250 kcmil 615 300 kcmil 450 300 kcmil 700 350 kcmil 525 350 kcmil 780 400 kcmil 600 400 kcmil 850 500 kcmil 725 500 kcmil 990 750 kcmil 950 750 kcmil 1300 1000 kcmil 1085 1000 kcmil 1565 Table 7 – Suggested initial test current to raise metric control conductor temperature 100°C Aluminum Conductor Copper Current Conductor (mm ) (Amperes) (mm ) 10 105 16 100 16 145 25 135 25 195 35 170 35 245 50 225 50 330 70 270 70 400 95 345 95 505 120 405 120 600 150 450 150 700 185 550 185 795 240 700 240 970 300 805 300 1100 400 930 400 1300 500 1085 500 1565 2 2 Current (Amperes) 9 ANSI C119.1-2006 http//:www.wangd.com 最专业的电气网站 7.3 Ambient conditions Current cycle tests shall be conducted in a space free from forced air currents or radiated heat striking (directly or indirectly) any portion of the test loop during the current-ON period. The ambient temperature, measured within 610 mm (2 ft) of the test loop at a location that minimizes the effect of thermal convection, shall be held between 15°C and 35°C. 7.4 Test current The current values in Tables 6 and 7 are the suggested initial test amperes for achieving the required temperature rise in the control conductor, and were selected to simplify current selection during test startup. The actual test current may need to be adjusted from these values to achieve the required conductor temperature rise. The tables cover commonly encountered conductor sizes. Some experimentation or extrapolation of the table values may be required for conductor sizes not shown. The currents provided are not intended to suggest current values for use in actual service. 7.5 Temperature conditions 7.5.1 CCT temperature conditions The current cycle test current shall be adjusted during the current-ON period of the first twenty-five (25) cycles to result in a steady-state temperature rise on the control conductor of 100°C to 105°C over ambient temperature for Class A. This current shall then be used during the remainder of the test current-ON periods, regardless of the temperature of the control conductor. 7.5.2 CCST temperature conditions The current cycle submersion test current shall be adjusted during the current-ON period of the first five (5) cycles to result in a steady-state temperature rise on the control conductor of 100°C to 105°C over ambient temperature for Class A. This current shall then be used during the remainder of the test current-ON periods, regardless of the temperature of the control conductor. 7.6 Current cycle periods Each test cycle shall consist of a current-ON and a current-OFF period. The time required to make resistance and temperature measurements is not considered a part of the current-ON or current-OFF time periods. 7.6.1 Current cycle-ON period The current-ON time is determined by reaching and maintaining thermal stability in the connector. Thermal stability is defined as not more than a variation of 2°C between any two (2) of three (3) readings taken at not less than 10 minute intervals. The length of the current-ON period shall not be less than that listed in Table 8 or Table 9, depending on the size of the control conductor. Table 8 – Minimum current cycle periods for AWG control conductors Aluminum Copper Current-ON Period (Hour) Up through 300 kcmil Up through #4/0 AWG 1.0 Over 300 through 750 kcmil Over #4/0 AWG through 500 kcmil 1.5 Over 750 kcmil Over 500 kcmil 2.0 10 ANSI C119.1-2006 http//:www.wangd.com 最专业的电气网站 Table 9 – Minimum current cycle periods for metric control conductors Aluminum Copper Up through 185 mm2 Up through 120 mm2 Current-ON Period (Hour) 1.0 Over 185 through 400 mm2 Over 120 through 240 mm2 1.5 Over 400 mm 7.6.2 2 Over 240 mm 2 2.0 CCT current cycle-OFF period Connectors tested by the Current Cycle Test (CCT) method shall cool in ambient temperature air. The duration of the current-OFF period for connectors tested by the CCT method shall initially be the same as the current-ON period. The duration may be reduced by forced air cooling after the first twenty-five (25) cycles. With the manufacturer's concurrence, forced air cooling may be initiated during the current-OFF period after the first (1st) cycle. The duration for the reduced current-OFF period shall be established by adding five (5) minutes to the time required for the four connectors to reach ambient temperature. 7.6.3 CCST current cycle-OFF period Connectors tested by the Current Cycle Submersion Test (CCST) method shall be immersed in still, chilled water (5°C ± 4°C) within thirty (30) seconds of the start of the current-OFF period. The connectors shall remain immersed in the chilled water for a minimum of fifteen (15) minutes after the temperature of the connector is reduced to the temperature of the water. The connectors shall be removed from the water before they are energized at the beginning of the next current-ON cycle. 7.7 Measurements Resistance and temperature measurements shall be made according to Table 10, depending on the choice of test method. When the number of measurement datums exceeds those specified in Table 10, the measurements nearest each specified cycle shall be used to evaluate performance. Table 10 – Resistance and temperature measurement intervals Current Cycle Test Method (CCT) Current Cycle Submersion Test Method (CCST) 25 – 30 5–7 45 – 55 8 – 12 70 – 80 18 – 22 95 – 105 28 – 32 120 – 130 38 – 42 160 – 170 48 – 52 200 – 210 58 – 62 245 – 255 68 – 72 320 – 330 78 – 82 400 – 410 88 – 92 495 – 505 98 – 102 11 ANSI C119.1-2006 http//:www.wangd.com 最专业的电气网站 7.7.1 Resistance measurements Resistance measurements shall be made at the end of a current-OFF period with all connectors thermally stabilized at the room ambient temperature. Thermal stability is defined as not more than a variation of 2°C between any two (2) of three (3) readings taken at not less than ten (10) minute intervals. Resistance measurements shall be made across each connector, between potential points located either on the equalizers a maximum of one conductor diameter from the edge adjacent to the conductor or at the midpoint of a solid conductor. A direct current shall be used for these measurements. The magnitude of the current selected shall not produce heating of the conductor that results in a noticeably changing measurement value during the period of current application. The current magnitude shall be sufficient to provide an accurate measurement above the noise threshold of the measurement instrumentation. The period of current application shall be as short as possible to achieve an accurate measurement. The applied test current shall be reported. NOTE—Typically, the dc current is less than ten percent (10%) of the test current. Ambient temperature shall be measured within 610 mm (2 ft) of the test loop at a location that minimizes the effect of thermal convection. The ambient temperature shall be recorded at the time of each set of resistance measurements. The resistance of each connector assembly shall be corrected from the measured temperature to 20°C. The corrected resistance values shall be used to evaluate the performance of the connectors. NOTE—The resistance values obtained shall be corrected to 20°C using the following formula: R20 = Rm / [1 + α (Tm - 20)] Where Rm is the measured resistance, Tm is the temperature (°C) of the connector and α is the resistance variation coefficient with the temperature. This coefficient can be taken equal to: α= 3.93 X 10-3/°C for copper α = 4.03 X 10-3/°C for aluminum NOTE—The values for the Resistance Variation Coefficient were derived from IEEE 837-2002, Standard for Qualifying Permanent Connections Used in Substation Grounding. 7.7.2 Temperature measurements Temperature measurements of the connectors, control conductors, and ambient air shall be made at the end of the specified current-ON cycle, immediately before the current is turned off. The temperatures shall be measured by means of thermocouples that have been permanently installed for the current cycle tests. At least one thermocouple shall be installed in the current path of each connector at a point where the highest temperature is anticipated. A suggested location for the thermocouples is shown in Annex D. One thermocouple shall be installed at the midpoint of the control conductor. 7.8 Maximum number of current cycles The number of cycles specified to complete the test may be extended to permit taking the final measurements during normal working hours. 7.9 Evaluation interval The evaluation of the connector performance, as specified in 5.2 and 5.3, shall be made on the basis of resistance and temperature measurements. 7.9.1 Evaluation by the CCT method The resistance and temperature measurements in accordance with 7.7 shall be used to evaluate connectors tested by the Current Cycle Test (CCT) method. 12 http//:www.wangd.com 最专业的电气网站 7.9.2 ANSI C119.1-2006 Evaluation by the CCST method The resistance and temperature measurements taken in accordance with 7.7 shall be used to evaluate connectors tested by the Current Cycle Submersion Test (CCST) method. 8 Tensile Strength 8.1 Test connectors 8.1.1 Number of samples Three samples of each connector-conductor combination shall be subjected to each mechanical test described in 8.2. 8.2 Pullout test 8.2.1 Pullout strength tests shall be performed on the following two conductor combinations for which the connector is designed: (1) the highest rated tensile strength conductor, and (2) the smallest diameter conductor with the highest rated tensile strength. 8.2.2 When conducting the tensile strength test, care shall be taken to ensure that all strands of the conductor are loaded simultaneously. 8.2.2.1 The load shall be applied at a cross-head speed not exceeding 20.6 mm per minute per meter (1/4 in. per minute per foot) of the total length of the exposed conductor between jaws. 8.2.2.2 The length of the exposed conductor between each gripping means and each connector shall not be less than 250 mm (10 in.). 8.2.2.3 The tensile strength shall be determined as the maximum load that can be applied. This load shall be measured to an accuracy of five percent (5%) with instruments calibrated according to ASTM E4. The mode of failure shall be recorded. 8.2.2.4 Minimum values indicated in 5.4.3 are required. 9 Thermal Stability of Insulated System Under Load (ISUL) 9.1 Test assembly (Refer to Annex C, Figure C.2 for suggested test loop diagram.) A minimum of two insulated connector systems shall be assembled in accordance with the recommendations of the connector manufacturer, on the combination of insulated input and output conductors that represents in number, size, and arrangement the most severe thermal condition for which the connector is designed. 9.2 Test conditions This test shall be conducted in a space free of forced air currents or radiated heat striking (directly or indirectly) any portion of the test loop during the current ON period. The ambient temperature, measured within 610 mm (2 ft) of the test loop at a location that minimizes the effect of thermal convection, shall be held between 15ºC and 35ºC. The ambient temperature shall not vary more than ±5°C during the entire test. 13 ANSI C119.1-2006 http//:www.wangd.com 最专业的电气网站 9.3 Test current The input current shall be adjusted to produce 90°C + 5°C on the hottest conductor. 9.4 Measurements The temperature of the input conductor shall be measured under the conductor insulation at a point 305 mm (12 in.) from the connector. The temperature of the connector shall be measured under the connector insulation in the current path between the input and output where the highest temperature is anticipated. A suggested location for the thermocouples is shown in Annex D. The temperature measurements shall be recorded a minimum of once every twelve (12) hours (plus or minus two (+/-2) hours) beginning with the seventy-second (72nd) hour (plus or minus two (+/-2) hours) and continuing through the one hundred twentieth (120th) hour. 10 Integrity of Seal and Connector Insulation 10.1 Assemblies for test Two (2) connector assemblies with the largest insulation diameters and two (2) connector assemblies with the smallest insulation diameters shall be tested in accordance with 10.2. Each assembly shall be assembled in accordance with the manufacturer's recommendations. 10.2 Procedural sequence Each connector assembly shall be subjected to the following in the order in which they are listed: 1. Water immersion for twenty-four (24) hours in accordance with 10.3. 2. Insulation resistance measurement in accordance with 10.4. 3. Dielectric withstand test in accordance with 10.5. 4. Heat conditioning in accordance with 10.6. 5. Flex in accordance with 10.7. 6. Twist in accordance with 10.8. 7. Water immersion for twenty-four (24) hours in accordance with 10.3. 8. Insulation resistance measurement in accordance with 10.4. 9. Cold conditioning in accordance with 10.9. 10. Flex in accordance with 10.7. 11. Twist in accordance with 10.8. 12. Water immersion for twenty-four (24) hours in accordance with 10.3. 13. Insulation resistance measurement in accordance with 10.4. 14. Current cycle and water submersion in accordance with 10.10. 15. Insulation resistance measurement in accordance with 10.4. 16. Dielectric withstand test in accordance with 10.5. 17. Leakage current test in accordance with 10.11. 10.3 Water immersion for twenty-four (24) hours All connector assemblies shall be immersed for twenty-four (24) hours in a tank that contains tap water at a temperature of 25°C ± 5°C. All parts of the connector assemblies, except leads, shall be at least 305 mm (12 in.) below the surface of the water. 14 http//:www.wangd.com 最专业的电气网站 10.4 ANSI C119.1-2006 Insulation resistance measurement While each connector assembly is immersed in accordance with 10.3, the insulation resistance shall be measured by applying a direct-current voltage of 500 volts or 1000 volts for one (1) minute, keeping the length of the immersed conductor constant, and then determining the insulation resistance at the voltage used. The total length of the immersed conductor with each connector assembly shall not exceed 1.83 m (6 ft). The conductor polarity shall be positive. If the tracking distance from the end of the conductor to the water surface is too short, a guarded circuit (see Annex E) shall be employed. 10.5 Dielectric withstand test While each connector assembly is immersed in accordance with 10.3 it shall be subjected to a 2.2-kV fifty (50) or sixty (60) Hertz test voltage for one (1) minute, applied between the water and the conductor. 10.6 Heat conditioning Each connector assembly shall be conditioned in an air-circulating oven at 90°C ± 5°C for seventy-two (72) hours. After the conditioning period, the connector assemblies shall be allowed to cool to a room temperature of 25°C + 5°C. 10.7 Flex Each connector assembly shall be subjected to the following: The insulated conductor shall be securely clamped at a distance from the joint as follows: For conductors that are #4 AWG and larger, fifteen (15) times the diameter of the insulated conductor. For conductors that are smaller than #4 AWG (16 mm2), twenty-five (25) times the diameter of the insulated conductor. The connectors shall be bent ninety (90) degrees to one side, returned to the starting position, bent ninety (90) degrees in the opposite direction, and returned to the starting position (see Figure 2). Each seal shall be subjected to ten (10) such flexing cycles. 10.8 Twist While clamped in accordance with 10.7, the connector shall be twisted around the conductor axis fifteen (15) degrees in one direction from the starting position, returned to the starting position, twisted fifteen (15) degrees in the other direction, and returned to the starting position (see Figure 2). Each connector assembly shall be subjected to five (5) such twisting cycles. Some bending is tolerated to allow both seals on one connector assembly to be twisted simultaneously. 10.9 Cold conditioning Each connector assembly shall be exposed for a minimum of four (4) hours in air having a temperature of -18°C + 5°C. Within five (5) minutes after removal from the cold conditioning, the assemblies shall be tested in accordance with 10.7 and 10.8. Both tests shall be completed within the five (5) minute time interval. 10.10 Current cycle and water submersion The connector assembly shall be connected in series with a control cable identical in size and type to that used in the connector assembly and then subjected to the following sequence of operations for fifty (50) cycles: 1. Heating by current in air. The current-ON period shall be one (1) hour using sufficient current to raise the temperature of the conductor of the control cable to 90°C + 5°C. 15 ANSI C119.1-2006 http//:www.wangd.com 最专业的电气网站 2. The current shall then be turned off and, within three (3) minutes, the connector shall be submersed in water having a temperature of 25°C ± 5°C for at least one half (1/2) hour. 10.11 Leakage current test Following the dielectric withstand test mentioned in 10.2 (16) and, while still immersed in the water, the connector assemblies are to be subjected to a six hundred (600) volt, fifty (50) or sixty (60) Hertz potential between the water and conductor and the resulting leakage current measured. 11 Test Report The test report shall include the necessary data to support conformance or nonconformance to the requirements of this standard, and also the following: • Date of test • Description of all test assemblies • Description of connectors and inhibiting compound before testing to ensure traceability • Description of conductors, including rated conductor strengths • Description of connector installation procedure • Current cycle and current stability amperage • Description of the condition of connectors after testing • Name and location of the test facility and personnel conducting the tests • Test Method: CCT, CCST • All options used in performance of the test including the mounting method (drilled or surface mounted) of the thermocouples. (Diagrams of test setup are desirable.) • Other pertinent information, such as installation details not specifically defined or required in this standard. • Certification (if required) 12 Marking 12.1 Connector system marking The principal component(s) of a connector system intended for direct burial or below grade use shall be marked with the manufacturer's name or trademark, the catalog number and wire range. The marking shall also be on the unit container (the smallest container in which the connector system is packaged). 12.2 Assembly instructions Assembly instructions shall be provided with the connector system. The assembly instructions shall be marked on the unit container or on an instruction sheet provided in each unit container. The assembly instructions shall include, but are not limited to: 1. Manufacturer’s name, part number and wire range, 2. Wire connector assembly instructions (strip length, torque, tooling, etc.) and 3. Connector system assembly instructions. 16 http//:www.wangd.com 最专业的电气网站 ANSI C119.1-2006 Note: H = distance determined in 10.7. Figure 2 – Flexing and twisting 17 ANSI C119.1-2006 http//:www.wangd.com 最专业的电气网站 Annex A (Informative) Optional Tests to Meet the Requirements of UL 486D If concurrent testing is being run to UL 486D, test sequences B, C, and D of UL 486D must also be run. 18 http//:www.wangd.com 最专业的电气网站 ANSI C119.1-2006 Annex B (Informative) Standards which are Applicable to C119.1 by Inference, but Not Directly Referenced in the Standard ASTM B8-86 Concentric Lay Stranded Copper Conductor, Hard, Medium Hard, or Soft ASTM B8-99 Standard Specification for Concentric-Lay-Stranded Copper Conductors, Hard, Medium-Hard, or Soft ASTM B231/B231M-99 Standard Specification for Concentric-Lay-Stranded Aluminum 1350 Conductors ASTM B400-01 Standard Specification for Compact Round Concentric-Lay-Stranded Aluminum 1350 Conductors ASTM B496-01 Standard Specification for Compact Round Concentric-Lay-Stranded Copper Conductors ASTM B784-01 Standard Specification for Modified Concentric-Lay-Stranded Copper Conductors for Use in Insulated Electrical Cables ASTM B786-02 Standard Specification for 19 Wire Combination Unilay-Stranded Aluminum Conductors for Subsequent Insulation ASTM B787/B787M-01 Standard Specification for 19 Wire Combination Unilay-Stranded Copper Conductors for Subsequent Insulation ANSI/ICEA S-81-570-2001 600 Volt Rated Cables of Ruggedized Design for Direct Burial Installations as Single Conductors or Assemblies of Single Conductors ANSI/ICEA S-105-692-2000 600 Volt Single Layer Thermoset Insulated Utility Underground Distribution Cables NEMA WC70-1999 /ICEA S-95-658 Non-Shielded Power Cables Rated 2000V or Less UL 486 D Insulated Wire Connector Systems for Underground Use or in Damp or Wet Locations UL 854 UL Standard for Safety Service-Entrance Cables Tenth Edition; Reprint with Revisions Through and Including 11/13/2002 19 ANSI C119.1-2006 http//:www.wangd.com 最专业的电气网站 Annex C (Informative) Test Loop Diagrams 1 Current Cycling Test Loop Diagram per 7.0 d T1 (minimum) d E1 E2 T2 E3 Tcc Power Supply 2d E4 T4 T3 E5 E6 Figure C.1 Current cycle loop schematic for CCT and CCST tests, as outlined in 7.0 Current Cycling in Air. “E” represents placement of equalizers on bare stranded, uninsulated cables. The minimum distance “d” between connector and equalizers, and between equalizers and power supply, is specified in Tables 4 and 5. Except at the connector, adjacent cables and equalizers must be a minimum of twenty (20) centimeters (eight (8) inches) apart to prevent thermal influences. Control Conductor is the length of cable between equalizers E3 and E4 and Tcc is the control conductor temperature. Connector resistance measurements are taken between successive equalizers, i.e., between E1 and E2, E2 and E3, etc. For more precise thermocouple positioning for measuring connector temperatures Ti, see Annex D. In addition to the five (5) temperature measurements indicated, the ambient air temperature is recorded, as per 7.7.2. 20 http//:www.wangd.com 最专业的电气网站 2 ANSI C119.1-2006 Thermal Stability of Insulated System Test Loop Diagram per 9.0 30 cm (12 in) Tc1 Ts1 Power Supply Ts2 Tc2 Figure C.2 Current cycle loop schematic for thermal stability of insulated system under load, as outlined in 9.0. Connectors have seals fully installed, utilizing insulated cables. See Annex D for suggested thermocouple positioning. In addition to the temperature measurements indicated, the ambient air temperature is recorded. The distance between connectors and power supply should, at minimum, be the distance specified in Tables 4 and 5 to minimize thermal interferences. Except at the connector, adjacent cables and equalizers must be a minimum of twenty (20) centimeters (eight (8) inches) apart to prevent thermal influences. 21 ANSI C119.1-2006 http//:www.wangd.com 最专业的电气网站 Annex D (Informative) Suggested Thermocouple Locations The locations shown are for illustration purposes only. Other locations may experience higher temperatures. Determination of the highest temperature point should be made and the thermocouples installed at that point. 1 Multiport Connector Test Setup Figure D.1 22 http//:www.wangd.com 最专业的电气网站 2 ANSI C119.1-2006 Splice Test Setup Figure D.2 23 ANSI C119.1-2006 http//:www.wangd.com 最专业的电气网站 Annex E (Informative) Guarded Circuit 1 Description A guarded circuit is used to eliminate or to minimize the current flow between the insulation and conductor ends, caused by surface leakage currents. 2 Setup A typical setup to measure insulation resistance is to submerge the test conductor and sample in water with both ends of the conductor exposed to air. Next, apply a test voltage between one exposed end of the test conductor and the water (which serves as ground). Resistance is calculated by dividing the known applied voltage by the measured current. Applying a voltage between the conductor and water causes current to flow. The current may go two ways, from the wire through the insulation to the water and from the exposed wire along the surface of the insulation to the water. The latter is called surface leakage current. To eliminate or minimize the surface leakage current from the measurement, create a guard by wrapping bare wire around the insulation near the exposed conductor ends keeping the exposed conductor ends, along with the bare wire, out of the water. The guards will capture or collect the current leakage along the insulation before it reaches the water. Two methods may be applied as shown in figures E.1 and E.2. 3 Circuit Diagrams Figure E.1 1) A = Ammeter 6) V = Voltage Source 2) I = Current Total; I = ISTRAY + IL 7) VG = Guard Voltage 3) IG = Guard Current 8) Figure E1, guard should be close to water, (no potential between water and guard), and current measured in water circuit 4) IL = Leakage Current 9) Figure E1, shows VG to water is 0V. 5) ISTRAY = Current along Insulation 24 http//:www.wangd.com 最专业的电气网站 ANSI C119.1-2006 Figure E.2 1) A = Ammeter 6) V = Voltage Source 2) I = Current Total; I = ISTRAY + IL 7) VG = Guard Voltage 3) IG = Guard Current 8) Figure E2, guard should be close to cable core, (no potential between core and guard), and current measured in cable core circuit 4) IL = Leakage Current 9) Figure E2 shows 0V between core and guard 5) ISTRAY = Current along Insulation § 25
