DRAFT

MALAYSIAN 14E005R1 j

STANDARD STAGE : PUBLIC COMMENT (40.20)

DATE : 01/08/2015 - 30/09/2015

Heavy duty crimp type cable lugs for use with XLPE insulated and circular compact copper conductors in single and multi core power cable applications up to 36 kV - Specification for the material, marking and dimensions (First revision)

OFFICER/SUPPORT STAFF: (ZZ /)

ICS: 29.060 Descriptors: crimp type cable lugs, XLPE insulated, compacted circular copper conductor, copper, single core and multi core power cable applications up to 36 kV, specification for material, marking, dimensions

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DEPARTMENT OF STANDARDS MALAYSIA

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Contents

Page Committee representation ..........................................................................................................ii Foreword .................................................................................................................................... iii Introduction ................................................................................................................................iv 1 Scope ............................................................................................................................ 1 2 Normative references ................................................................................................... 1 3 Definition ....................................................................................................................... 1 4 Requirements ............................................................................................................... 2

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Committee representation The Industry Standards Committee on Generation, Transmission and Distribution of Energy (ISC E) under whose authority this Malaysian Standard was developed, comprises representatives from the following organisations: Association of Consulting Engineers Malaysia Department of Standards Malaysia Federation of Malaysian Manufacturers Jabatan Kerja Raya Malaysia Malaysia Nuclear Power Corporation Malaysian Association of Standards Users Malaysian Cable Manufacturers Association Malaysian Electrical Appliances and Distributors Association Malaysian Green Technology Corporation Persatuan Kontraktor Elektrikal dan Mekanikal Melayu Malaysia SIRIM Berhad (Secretariat) SIRIM QAS International Sdn Bhd Sabah Electricity Sdn Bhd Sarawak Energy Berhad Suruhanjaya Komunikasi dan Multimedia Malaysia Suruhanjaya Tenaga Sustainable Energy Development Authority Malaysia Tenaga Nasional Berhad The Electrical and Electronics Association of Malaysia The Institution of Engineers, Malaysia Universiti Malaya The Technical Committee on Electrical Installation, Protection and Insulation Practice which developed this Malaysian Standard was managed by The Electrical and Electronics Association of Malaysia (TEEAM) in its capacity as an authorised Standards Writing Organisation and consists of representatives from the following organisations: Association of Consulting Engineers Malaysia EITA Resources Berhad G. H. Liew Engineering (1990) Sdn Bhd Jabatan Bomba dan Penyelamat Malaysia Jabatan Kerja Raya Malaysia Sabah Electricity Sdn Bhd Sarawak Energy Berhad SIRIM QAS International Sdn Bhd Suruhanjaya Tenaga Tenaga Nasional Berhad (Distribution Division) Tenaga Nasional Berhad (Generation Division) The Electrical and Electronics Association of Malaysia (Secretariat) The Institution of Engineers, Malaysia Time Era Sdn Bhd Universiti Malaya The Working Group on Cable lugs, Tools and Dies which developed this Malaysian Standard consists of representatives from the following organisations: Abbaco Controls Sdn Bhd Conway Terminals Manufacturer Sdn Bhd Covis Sdn Bhd The Electrical and Electronics Association of Malaysia (Secretariat) The Institution of Engineers, Malaysia

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Foreword This Malaysian Standard was developed by the Technical Committee on Electrical Installation, Protection and Insulation Practice under the authority of the Industry Standards Committee on Generation, Transmission and Distribution of Energy. Development of this standard was carried out by The Electrical and Electronics Association of Malaysia (TEEAM) which is the Standards Writing Organisation (SWO) appointed by SIRIM Berhad to develop standards for electrical installation, protection and insulation practice. This Malaysian Standard cancels and replaces MS 1838:2005, Heavy duty crimp type cable lugs for use with XLPE insulated and circular compact copper conductors in single and multi core power cable applications up to 36 Kv - Specification for the material, marking and dimensions. Compliance with a Malaysian Standard does not of itself confer immunity from legal obligations.

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Introduction This Malaysian Standard is meant to standardise and to prevent the use of inferior and unsuitable cable lugs in the connection of conductors to electrical equipment, in view of its widespread use. This Malaysian Standard containing the guidelines for the overall installed cable lug dimensions is aimed at achieving this goal. In the development of this standard specification, due consideration was made to the current practices existing in the industry concerned, and careful consideration of the common usage of crimping tools and dies. The earlier MS 1540: 2002, Specification for the material, marking and dimensions of crimp type cable lugs for use with copper conductors in low voltage applications was developed for PVC insulated copper conductors in single and multi core power cables and secondary wiring with cross-sections 1.5 mm2 to 1000 mm2. XLPE insulated and copper conductors have higher current capacities than their PVC insulated counter-parts. The reason being, the

thermal rating of XLPE insulated cables is 90 C, compared to 70 C for PVC insulated cables. XLPE insulated single & multi core cables are economically suitable for power cables and therefore the optimum cross-sections have been selected for a range of: 25 mm2 to 630 mm2. Because XLPE is a superior dielectric material, it is best applied as the insulating medium for higher voltage cables. Therefore, this standard is for the specification for material, marking and dimensions of heavy duty crimp type cable lugs for use in XLPE insulated and circular compact copper conductors in single and multi core power cable applications up to 36 kV. A XLPE insulated and circular compact copper conductor single and multi core cable have an overall conductor diameter which is smaller than that of a counterpart standard PVC insulated single and multi core cable. Therefore, cable lugs to MS 1540:2002 do not match-fit XLPE insulated and circular compact copper conductors; because the lugs barrel inside diameter are bigger. Without suitable specification as this standard, very often "oversized" standard cable lugs are crimped onto XLPE cables, resulting in unfit situations. Or, on the other hand "undersized" standard lugs used; for example, a 150 mm2 standard cable lug to MS 1540:2002 fits a 185 mm2 XLPE insulated and circular compact copper conductor single & multi core cable. What a paradox and how unsafe the application; the capacity of the cable being higher than the cable lug. This standard is therefore developed to avoid dangerous applications, and thus help to ensure electrical installations are safe. For

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Heavy duty crimp type cable lugs for use with XLPE insulated and circular compact copper conductors in single and multi core power

cable applications up to 36 kV - Specification for the material, marking and dimensions (First revision)

1 Scope This Malaysian Standard specifies the construction and the overall installed dimensions of heavy duty crimp type cable lugs for use with XLPE insulated and circular compact copper conductors in single and multi core power cable applications up to 36 kV. Dimensions are provided for the full length, internal diameter of barrel, thickness of barrel, clearance hole for bolt mounting and chamfer on the lug barrel. This standard specifies the types of construction material specification, finishing and markings cable lug. This standard applies to terminal lugs for the circular compact copper conductors of XLPE insulated single and multi core power cables with cross-sections 25 mm2 to 630 mm2. This standard is applicable to cable lugs for both low voltage (LV) applications i.e. up to a maximum of 1 kV, and medium voltage (MV) applications of greater than 1 kV but up to a maximum of 36 kV. This standard is applicable to cable lugs with one hole in the palm.

2 Normative references The following normative references are indispensable for the application of this standard. For dated references, only the edition cited applies. For undated references, the latest edition of the normative reference (including any amendments) applies. IEC 60228, Conductors of insulated cables IEC 60502-2, Power cables with extruded insulation and their accessories for rated voltages from 1 kV (Um-36 kV) - Part 2: Cables for rated voltages of 6 kV (Um-72 kV) and (Um-36kV) IEC 61238-2, Compression and mechanical connectors for power cables with copper or aluminium conductors - Part 2: Terminal lugs for power cables to fit equipment up to and including 1 kV - Overall dimensions.

3 Terms and definitions For the purposes of this standard, the following terms and definitions apply. 3.1 connector Device for connecting a conductor to an equipment terminal or for connecting two or more conductors to each other.

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3.2 cable lug Connector comprising a palm and a connector barrel, for connecting a conductor to an equipment terminal. The cable lug mentioned in this standard, applies to crimp type cable lugs for low voltage and medium voltage applications. 3.3 palm Part of a cable lug used to make the connection to equipment terminals. 3.4 connector barrel Part of a connector, into which the conductor to be connected is introduced. 3.5 joint Assembly comprising the connector barrel and that portion of the conductor which has been brought into immediate contact with it during the crimping process.

3.6 crimp Method of securing a connector to a conductor by using a special tool to produce permanent deformation of the connector and the conductor.

4 Requirements 4.1 Construction The construction for heavy duty cable lugs for low voltage applications and that for medium voltage applications are given in Figures 1 and 2 respectively.

Figure 1. Construction of low voltage application heavy duty cable lug

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Figure 2. Construction of medium voltage application heavy duty cable lug (Remark: Remove all sharp edges)

4.2 Material specification (For both low voltage and medium voltage applications) 4.2.1 The copper for cable lugs shall comply with the specifications given in Table 1.

Table 1. Material specification for cable lugs

Description Specification

Material type Copper

Grade of copper Electrolytic copper (ETP)

Electrical conductivity of copper 99% IACSa

Purity of copper 99.9%

a IACS - International Annealed Copper Standard

4.2.2 The finishing for cable lugs shall comply with the specifications given in Table 2.

Table 2. Finishing specification for cable lugs

Description Specification

Finishing type Electro-tinplating

Purity of tin 99%

Minimum thickness of tin plating 3 micron

4.3 Markings (For both low voltage and medium voltage applications) Cable lugs shall be clearly marked by stamping the conductor size on the palm of the cable lugs, as shown in Figure 3 and 4.

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Figure 3. Example of marking on LV cable lugs

Figure 4. Example of marking on MV cable lug

Key 1 Manufacturer’s symbol representative (for the minimum size of 70 mm2 and above) 2 Suitable conductor size 3 Cable lug material and corresponding cable material type (for the minimum size of

70 mm2 and above) 4 “X” - A mark to represent XLPE insulated compacted circular cable 4.4 Dimensions (For both low voltage and medium voltage applications)

The legend for the various dimensions of this standard is shown in Figure 5 and 6.

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Figure 5. Legend showing the dimensions of the LV cable lug

Figure 6. Legend showing the dimensions of the MV cable lug Dimensions as specified in Figure 5 and 6 are detailed in Table 3.

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Table 3. Overall installed dimensions for crimp type cable lugs for 1 kV and 36 kV

Cable lug size/ Wire

size (mm2)

Full length (FL) (mm)

Connector length (CL)

(mm)

Internal diameter

(ID)

(mm)

Width (W)

(mm)

Thickness (t)

(mm)

Clearance

hole for bolt

mounting

25 36 16.0 6.3 13.5 1.50 8.2 (M8)

35 44 17.0 7.4 16.0 1.70 10.5 (M10)

50 48 20.0 8.6 18.0 1.95 10.5 (M10)

70 53 21.0 10.3 20.5 2.05 12.8 (M12)

95 58 24.0 12.3 25.0 2.60 12.8 (M12)

120 62 28.0 14.2 29.0 2.90 12.8 (M12)

150 70 30.0 15.6 31.5 3.20 16.8 (M16)

185 78 32.0 17.5 37.0 3.25 16.8 (M16)

240 113 43.0 20.0 41.0 4.30 16.8 (M16)

300 117 44.0 22.3 46.5 4.75 16.8 (M16)

400 118 45.0 24.2 50.0 5.10 16.8 (M16)

500 136 52.0 28.0 55.0 5.30 20.0 (M20)

630 143 52.0 32.0 64.0 6.35 20.0 (M20)

800 170 66.0 37.0 71.5 6.8 -

1000 200 86.0 40.2 79.5 8.0 -

NOTES: 1. Allow ± 1% tolerance on all FL, CL and W dimensions. 2. For ID: 10 mmø and below, allow 0.1 mm tolerance; and above 10 mmø, allow 0.2 mm tolerance. 3. Allow ± 3% tolerance on t. 4. FL & CL will be minimum length. 5. I.D. for compacted circular conductor only.

4.4.1 Chamfer on barrel for low voltage and medium voltage cable lug

To assist easy entry of cable into the lug, a chamfer of 30 to 45 shall be provided on the inner edge of the barrel inlet, as shown in Figure 7 and 8.

Figure 7. Chamfer on LV cable lug

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Figure 8. Chamfer on MV cable lug

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Acknowledgements Members of Technical Committee on Electrical Installation, Protection and Insulation Practice Ir Rocky Wong Hon Thang (Chairman) Puan Khong Choy Tai (Secretary) Ir Ahmad Rashidi Zainudin Mr Lim Siang Leong Ir Chew Shee Fuee Dato’ Rusmani Muhamad Dato’ Ir Mohd Fazli Osman/ Ir Nizar Othman Mr Khung Chiang Sing/ Mr Chong Kok Leong Mr Hii Hii Kwong Mr Surian Rasol Haji Abdul Aziz Abdul Rahman Ir Tan Chow Heang Mr Nur Azlan Abdul Malek Mr Nageswara Rao Prof Dr Hew Wooi Ping/ Dr Che Hnag Seng

The Electrical and Electronics Association of Malaysia The Electrical and Electronics Association of Malaysia Association of Consulting Engineers Malaysia EITA Resources Berhad G. H. Liew Engineering (1990) Sdn Bhd Jabatan Bomba dan Penyelamat Malaysia Jabatan Kerja Raya Malaysia Sabah Electricity Sdn Bhd Sarawak Energy Berhad SIRIM QAS International Sdn Bhd Suruhanjaya Tenaga Tenaga Nasional Berhad (Distribution Division) Tenaga Nasional Berhad (Generation Division) Time Era Sdn Bhd Universiti Malaya

Members of Working Group on Cable lugs, Tools and Dies Ir Rocky Wong Hon Thang (Chairman) Ms Khong Choy Tai (Secretary) Ir Chang Yew Cheong Mr Ng Choon Guan/ Mr Albert Tan Mr Lawrence Lai Kun Hoong Ir Lim Kim Ten

The Electrical and Electronics Association of Malaysia The Electrical and Electronics Association of Malaysia Abbaco Controls Sdn Bhd Conway Terminals Manufacturer Sdn Bhd Covis Sdn Bhd The Institution of Engineers, Malaysia

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