ansi c119.1-2006

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ANSI C119.1-2006

American National Standard

for Electric Connectors

Sealed Insulated UndergroundConnector Systems

Rated 600 Volts

http//:www.wangd.com

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ANSI C119.1-2006

American National Standard

For Electric Connectors

Sealed Insulated Underground Connector SystemsRated 600 Volts

Secretariat:

National Electrical Manufacturers Association

Approved January 13, 2006

American National Standards Institute, Inc.


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NOTICE AND DISCLAIMER

The information in this publication was considered technically sound by the consensus ofpersons engaged in the development and approval of the document at the time it was

developed. Consensus does not necessarily mean that there is unanimous agreementamong 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 processbrings together volunteers and/or seeks out the views of persons who have an interest in thetopic covered by this publication. While NEMA administers the process and establishes rules topromote fairness in the development of consensus, it does not write the document and it doesnot independently test, evaluate, or verify the accuracy or completeness of any information orthe soundness of any judgments contained in its standards and guideline publications.

NEMA disclaims liability for any personal injury, property, or other damages of any naturewhatsoever, whether special, indirect, consequential, or compensatory, directly or indirectly

resulting from the publication, use of, application, or reliance on this document. NEMAdisclaims and makes no guaranty or warranty, express or implied, as to the accuracy orcompleteness of any information published herein, and disclaims and makes no warranty thatthe information in this document will fulfill any of your particular purposes or needs. NEMA doesnot undertake to guarantee the performance of any individual manufacturer or sellers productsor services by virtue of this standard or guide.

In publishing and making this document available, NEMA is not undertaking to renderprofessional or other services for or on behalf of any person or entity, nor is NEMAundertaking to perform any duty owed by any person or entity to someone else. Anyone usingthis document should rely on his or her own independent judgment or, as appropriate, seekthe advice of a competent professional in determining the exercise of reasonable care in anygiven circumstances. Information and other standards on the topic covered by this publicationmay be available from other sources, which the user may wish to consult for additional viewsor information not covered by this publication.

NEMA has no power, nor does it undertake to police or enforce compliance with the contentsof this document. NEMA does not certify, test, or inspect products, designs, or installations forsafety or health purposes. Any certification or other statement of compliance with any healthor safetyrelated information in this document shall not be attributable to NEMA and is solelythe responsibility of the certifier or maker of the statement.


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AMERICANNATIONAL

STANDARD

Approval of an American National Standard requires verification byANSI that the requirements for due process, consensus, and othercriteria for approval have been met by the standards developer.

Consensus is established when, in the judgment of the ANSI Board of

Standards Review, substantial agreement has been reached by directlyand materially affected interests. Substantial agreement means muchmore than a simple majority, but not necessarily unanimity. Consensusrequires that all views and objections be considered, and that aconcerted effort be made toward their resolution.

The use of American National Standards is completely voluntary; theirexistence does not in any respect preclude anyone, whether he hasapproved the standards or not, from manufacturing, marketing,purchasing, or using products, processes, or procedures notconforming to the standards.

The American National Standards Institute does not develop standards

and will in no circumstances give an interpretation of any AmericanNational Standard. Moreover, no person shall have the right orauthority to issue an interpretation of an American National Standard inthe name of the American National Standards Institute. Requests forinterpretations should be addressed to the secretariat or sponsorwhose name appears on the title page of this standard.

Caution Notice: This American National Standard may be revised orwithdrawn at any time. The procedures of the American NationalStandards Institute require that action be taken periodically to reaffirm,revise, or withdraw this standard. Purchasers of American NationalStandards may receive current information on all standards by calling orwriting the American National Standards Institute.

Published by:

National Electrical Manufacturers Association

1300 North 17th Street, Rosslyn, VA 22209

Copyright 2006 by National Electrical Manufacturers AssociationAll rights reserved including translation into other languages, reserved under the Universal CopyrightConvention, the Berne Convention for the Protection of Literary and Artistic Works, and theInternational 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 writtenpermission of the publisher.

Printed in the United States of America.


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Contents

Page

Foreword ........................................................................................................................ vii

1 Scope and Purpose .......................................................................................................1

1.1 Scope ............................................................................................................. 1

1.2 Purpose.............................................................................................................1

2 Referenced American National Standard ......................................................................1

3 Definitions .............................................................................................................1

4 Test Conditions ..............................................................................................................2

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

5 Performance...................................................................................................................2

5.1 General ............................................................................................................. 2

5.2 Resistance ........................................................................................................3

5.2.1 CCT resistance ....................................................................................3

5.2.2 CCST resistance..................................................................................3

5.3 Temperature......................................................................................................3

5.3.1 CCT temperature .................................................................................3

5.3.2 CCST temperature...............................................................................35.3.3 Stability determination for CCT and CCST3

5.4 Mechanical tests ...............................................................................................3

5.4.1 Tensile strength ...................................................................................3

5.4.2 Rated conductor strength ....................................................................3

5.4.3 Tension ................................................................................................3

5.5 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

5.6 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


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6 Test Procedures, General..............................................................................................5

6.1 Test connectors ................................................................................................5

6.1.1 Description ...........................................................................................5

6.1.2 Family sample set ................................................................................5

6.2 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

7 Current Cycling in Air .....................................................................................................6

7.1 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

7.2 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

7.5.1 CCT temperature conditions..............................................................10

7.5.2 CCST temperature conditions ...........................................................10

7.6 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

7.7 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


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7.9.1 Evaluation by the CCT method..........................................................12

7.9.2 Evaluation by the CCST method .......................................................13

8 Tensile Strength...........................................................................................................13

8.1 Test connectors ..............................................................................................13

8.1.1 Number of samples............................................................................13

8.2 Pullout test ......................................................................................................13

9 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 ......................................................................................1410.3 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


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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 100C ......9

7 Suggested initial test current to raise metric control conductor temperature 100C .....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)

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


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Foreword (Neither this foreword nor any of the informative annexes is a part of American National StandardC119.1-2006.)

The standard covers electrical, mechanical, and sealing requirements of connectors rated 600 volts andinstalled underground.

This standard was initially developed by an EEI-NEMA Joint Committee on Underground DistributionConnectors 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 Association1300 North 17th Street, Suite 1752Rosslyn, VA 22209

This standard was processed and approved for submittal to ANSI by the Accredited Standards Committeeon 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, ChairmanRonald Lai, Vice ChairmanVince Baclawski, Secretary

Organization Represented: Name of Representative:

Aluminum Association Jean-Marie Asselin

Electric Utility Industry Warren HadleyDouglas HarmsJames HarrisHarry HayesCurt SchultzJames SprecherGerald WasielewskiDavid West

National Electric Energy Testing, Research & Application Center Thomas Champion

National Electric Manufacturers Association David DembowskiPierre GuyotBarry JohnsonRonald LaiFrank Muench

Greg NienaberFrank StepniakCarl TammCarl TaylorDavid Thompson

Allen WilcoxJames Zahnen

Rural Utilities Service (RUS) Trung Hiu


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Tennessee Valley Authority Jeffrey Nelson

Underwriters Laboratories, Inc. Jake Killinger

Other Peter BowersStanley Hodgin

The C119.1 Subcommittee on Sealed Underground Connector Systems, which developed the revisions ofthis standard, had the following members:

James Zahnen, ChairmanDavid West, Vice ChairmanVince 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 TaylorRichard (Jeff) J. Waidelich

Gerald Wasielewski

David West

Allen Wilcox

James Zahnen


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1

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) voltsfor utility applications and establishes electrical, mechanical, and sealing requirements for sealedunderground connector systems.

1.2 Purpose

The purpose of this standard is to give reasonable assurance to the user that sealed, insulatedunderground connector systems meeting the requirements of this standard will perform in a satisfactorymanner, provided they have been properly selected for the intended application and are installed inaccordance with the manufacturers recommendations.

2 Referenced American National Standard

This standard is intended to be used in conjunction with the following standards. When this referencedstandard is superseded by a revision approved by the American National Standards Institute, thereferenced 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 doneusing 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 continuouselectrical 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 thatwould be at the highest temperature.

guarded circuit: A circuit used to eliminate or to minimize the current flow between the insulation andconductor ends, caused by surface leakage currents.

input conductor: Supply side of the connector assembly.

AMERICAN NATIONAL STANDARD ANSI C119.1-2006


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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 inaccordance 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 Number of Test Cycles for:

CCT Method CCST Method

Heavy Duty (Class A) 500 100

NOTEThe 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 notexhibit high thermal expansion and creep characteristics.

NOTEThis 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 testedin accordance with the methods specified in 7.0 through 10.0.


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5.2 Resistance

The resistance of the connection tested in accordance with 7.0 shall be stable. Stability is achieved if anyresistance measurement, including allowance for measurement error, does not vary by more than plus orminus five percent (+/-5%) from the average of all the measurements at specified intervals during thecourse of the test.

5.2.1 CCT resistanceThe resistance of the connection tested by the Current Cycle Test method in accordance with 7.0 shall bestable between the twenty-fifth (25th) cycle and the completion of the number of current cycles required in4.2.

5.2.2 CCST resistance

The resistance of the connection tested by the Current Cycle Submersion Test method in accordancewith 7.0, shall be stable between the tenth (10th) cycle and the completion of the number of currentcycles required in 4.2.

5.3 Temperature

The temperature of the connector tested in accordance with 7.0 shall not exceed the temperature of thecontrol 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 thetwenty-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 stablebetween 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 thecontrol conductor and the connector, including allowance for measurement error, is not more than 10C

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 thevalues 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 applicableASTM standard listed in Annex B, or as furnished by the conductor manufacturer for nonstandardconductors.

5.4.3 Tension

The tensile strength of the connector shall be equal to or greater than five percent (5%) of the ratedconductor strength of the weaker of the conductors being joined, but not less than the values in Table 2or Table 3.


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5.5.3 Insulation

The insulation provided as part of the connector system shall show no visible evidence of deteriorationwhen 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 withstandrepeated handling during underground installation.

5.6.1 Insulation resistance

When tested in accordance with 10.2(2), the connector assemblies shall have an insulation resistancegreater 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 1x103megohms for all other conditions.

The latter criterion applies because of the extremely high resistance values and the difficulty inaccurately 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) withoutbreakdown.

5.6.3 Leakage current

The leakage current of the assemblies shall not exceed 1 milliampere when tested in accordance with10.2(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 inthe 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 through10.0, 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 brushuntil the entire contact area of the conductor is clean.


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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 coatedwith particle-free petroleum jelly.

NOTEThis 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 isrequired 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'sinstructions.

7 Current Cycling in Air7.1 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 innumber, 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. Theconnector 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-copperconductors, 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, asdetermined in 7.1.1.

7.1.3 Equalizers

To provide equipotential planes for resistance measurements and to prevent the influence of oneconnector on another, equalizers shall be installed in stranded conductor on each side of each connectorin the current cycle loop. Equalizers are not required on solid conductors. Any form of equalizer thatensures 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 betweenthe connectors, with an equalizer in the center. If a compression sleeve is employed as an equalizer withaluminum 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 theconnectors of solid conductors in the current cycle loop, shall be in accordance with Tables 4 and 5. Theconductor length in Tables 4 and 5 does not include the length within the connector or equalizer. In


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addition, where connector design permits, the conductor end shall project 12.7 mm (1/2 in.) beyond theconnector contact groove. The equalizers at each end of the current cycle loop shall be joined to thepower source with additional lengths of the test conductor to be not less than the lengths specified inTables 4 and 5.

Table 4 Conductor lengths for current cycle tests, AWG sizes

Conductor Type Exposed length

Aluminum 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 Exposed length

Aluminum Copper Stranded Solid

m in.* m in.*

120 mm2and Below 70 mm

2and Below 0.3 12 0.6 24

Over 120 mm

2

through 380 mm

2

Over 70 mm

2

through 240 mm

2

0.6 24 1.2 48

Over 380 mm2 Over 240 mm

2 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 twoequalizers for stranded conductors). The control conductor shall be the same type and size as theconductor in the current cycle loop that will be at the highest temperature. The length of the controlconductor 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 Table6 or 7 the conductor in the current cycle loop that has the least test current for equivalentaluminum/copper conductors.

7.1.7 Multiple control conductors

If the test loop includes different conductors, and a question arises as to which conductor causes thehighest temperature rise, a control conductor of each type is required. The test current shall cause thehigher temperature rise in one of the control conductors to meet the requirements of 7.5.


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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 least610 mm (24 in.) from the floor and the ceiling. An example of a vertical test configuration is shown inFigure 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 thecurrent-ON period, no part of the circuit shall be less than 200 mm (8 in.) above the surface of the chilledwater. At the beginning of the current-OFF period, the connectors and the control conductor shall besubmerged to a minimum of 100 mm (4 in.) below the water surface.


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Table 6 Suggested initial test current

to raise AWG control conductor temperature 100C

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 100C

Aluminum Copper

Conductor Current Conductor Current

(mm2) (Amperes) (mm

2) (Amperes)

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 505120 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


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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 15C and 35C.

7.4 Test current

The current values in Tables 6 and 7 are the suggested initial test amperes for achieving the requiredtemperature rise in the control conductor, and were selected to simplify current selection during teststartup. The actual test current may need to be adjusted from these values to achieve the requiredconductor temperature rise. The tables cover commonly encountered conductor sizes. Someexperimentation or extrapolation of the table values may be required for conductor sizes not shown. Thecurrents 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 100C to 105C overambient temperature for Class A. This current shall then be used during the remainder of the testcurrent-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 100C to 105C overambient temperature for Class A. This current shall then be used during the remainder of the testcurrent-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-OFFtime 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 2C between any two (2) of three (3) readingstaken at not less than 10 minute intervals. The length of the current-ON period shall not be less than thatlisted 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


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Table 9 Minimum current cycle periods for metric control conductors

Aluminum Copper Current-ON Period(Hour)

Up through 185 mm2 Up through 120 mm

2 1.0

Over 185 through 400 mm2 Over 120 through 240 mm

2 1.5

Over 400 mm2 Over 240 mm2 2.0

7.6.2 CCT current cycle-OFF period

Connectors tested by the Current Cycle Test (CCT) method shall cool in ambient temperature air. Theduration of the current-OFF period for connectors tested by the CCT method shall initially be the same asthe 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-OFFperiod after the first (1st) cycle. The duration for the reduced current-OFF period shall be established byadding 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 (5C 4C) within thirty (30) seconds of the start of the current-OFF period. The connectorsshall remain immersed in the chilled water for a minimum of fifteen (15) minutes after the temperature ofthe connector is reduced to the temperature of the water. The connectors shall be removed from thewater 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 thechoice 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 SubmersionTest 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


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7.7.1 Resistance measurements

Resistance measurements shall be made at the end of a current-OFF period with all connectors thermallystabilized at the room ambient temperature. Thermal stability is defined as not more than a variation of2C 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 eitheron the equalizers a maximum of one conductor diameter from the edge adjacent to the conductor or atthe midpoint of a solid conductor. A direct current shall be used for these measurements. Themagnitude of the current selected shall not produce heating of the conductor that results in a noticeablychanging measurement value during the period of current application. The current magnitude shall besufficient to provide an accurate measurement above the noise threshold of the measurementinstrumentation. The period of current application shall be as short as possible to achieve an accuratemeasurement. The applied test current shall be reported.

NOTETypically, 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 minimizesthe effect of thermal convection. The ambient temperature shall be recorded at the time of each set ofresistance measurements. The resistance of each connector assembly shall be corrected from themeasured temperature to 20C. The corrected resistance values shall be used to evaluate the

performance of the connectors.

NOTEThe resistance values obtained shall be corrected to 20C using the following formula:

R20= Rm/ [1 + (Tm- 20)]

Where Rmis the measured resistance, Tmis the temperature (C) of the connector and is the resistancevariation coefficient with the temperature. This coefficient can be taken equal to:

= 3.93 X 10-3

/C for copper

= 4.03 X 10-3

/C for aluminum

NOTEThe values for the Resistance Variation Coefficient were derived from IEEE 837-2002, Standard for Qualifying PermanentConnections Used in Substation Grounding.

7.7.2 Temperature measurements

Temperature measurements of the connectors, control conductors, and ambient air shall be made at theend of the specified current-ON cycle, immediately before the current is turned off. The temperaturesshall be measured by means of thermocouples that have been permanently installed for the current cycletests. At least one thermocouple shall be installed in the current path of each connector at a point wherethe 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 finalmeasurements 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 ofresistance 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 evaluateconnectors tested by the Current Cycle Test (CCT) method.


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7.9.2 Evaluation by the CCST method

The resistance and temperature measurements taken in accordance with 7.7 shall be used to evaluateconnectors 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 testdescribed in 8.2.

8.2 Pullout test

8.2.1 Pullout strength tests shall be performed on the following two conductor combinations for whichthe 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 theconductor 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.

8.2.2.2The length of the exposed conductor between each gripping means and each connector shall notbe 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 loadshall 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 therecommendations of the connector manufacturer, on the combination of insulated input and outputconductors that represents in number, size, and arrangement the most severe thermal condition for whichthe 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 orindirectly) any portion of the test loop during the current ON period. The ambient temperature, measuredwithin 610 mm (2 ft) of the test loop at a location that minimizes the effect of thermal convection, shall beheld between 15C and 35C. The ambient temperature shall not vary more than 5C during the entiretest.


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9.3 Test current

The input current shall be adjusted to produce 90C + 5C on the hottest conductor.

9.4 Measurements

The temperature of the input conductor shall be measured under the conductor insulation at a point 305mm (12 in.) from the connector. The temperature of the connector shall be measured under the connectorinsulation 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 orminus 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.



9. Cold conditioning in accordance with 10.9.

10. Flex in accordance with 10.7.

11. Twist in accordance with 10.8.



14. Current cycle and water submersion in accordance with 10.10.


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 25C 5C. All parts of the connector assemblies, except leads, shall be at least 305mm (12 in.) below the surface of the water.


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10.4 Insulation resistance measurement

While each connector assembly is immersed in accordance with 10.3, the insulation resistance shall bemeasured by applying a direct-current voltage of 500 volts or 1000 volts for one (1) minute, keeping thelength 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 90C 5C for seventy-two(72) hours. After the conditioning period, the connector assemblies shall be allowed to cool to a room

temperature of 25C + 5C.

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 insulatedconductor.

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 connectorassembly 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-18C + 5C. 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 timeinterval.

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 thatused 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 sufficientcurrent to raise the temperature of the conductor of the control cable to 90C +5C.


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2. The current shall then be turned off and, within three (3) minutes, the connector shall be

submersed in water having a temperature of 25C 5C 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, theconnector 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 therequirements 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 surfacemounted) of the thermocouples. (Diagrams of test setup are desirable.)

Other pertinent information, such as installation details not specifically defined or required inthis 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. Manufacturers name, part number and wire range,2. Wire connector assembly instructions (strip length, torque, tooling, etc.) and

3. Connector system assembly instructions.


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Note: H = distance determined in 10.7.

Figure 2 Flexing and twisting


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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 alsobe run.


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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 Aluminum1350 Conductors

ASTM B400-01 Standard Specification for Compact Round Concentric-Lay-StrandedAluminum 1350 Conductors

ASTM B496-01 Standard Specification for Compact Round Concentric-Lay-StrandedCopper Conductors

ASTM B784-01 Standard Specification for Modified Concentric-Lay-Stranded CopperConductors for Use in Insulated Electrical Cables

ASTM B786-02 Standard Specification for 19 Wire Combination Unilay-StrandedAluminum Conductors for Subsequent Insulation

ASTM B787/B787M-01 Standard Specification for 19 Wire Combination Unilay-Stranded CopperConductors for Subsequent Insulation

ANSI/ICEA S-81-570-2001 600 Volt Rated Cables of Ruggedized Design for Direct BurialInstallations as Single Conductors or Assemblies of Single Conductors

ANSI/ICEA S-105-692-2000 600 Volt Single Layer Thermoset Insulated Utility Underground

Distribution CablesNEMA 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 Dampor Wet Locations

UL 854 UL Standard for Safety Service-Entrance Cables Tenth Edition; Reprintwith Revisions Through and Including 11/13/2002


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Annex C(Informative)

Test Loop Diagrams

1 Current Cycling Test Loop Diagram per 7.0

(minimum) d

2d

d

T1

T4

T3

T2

E1

E2

E3

E6

E5

E4

TccPower

Supply

(minimum) d

2d

d

T1

T4

T3

T2

E1

E2

E3

E6

E5

E4

TccPower

Supply

Power

Supply

Figure C.1

Current cycle loop schematic for CCT and CCST tests, as outlined in 7.0 Current Cycling in Air. Erepresents 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 4and 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 ofcable between equalizers E3 and E4 and Tcc is the control conductor temperature. Connector resistancemeasurements are taken between successive equalizers, i.e., between E1 and E2, E2 and E3, etc. Formore precise thermocouple positioning for measuring connector temperatures Ti, see Annex D. Inaddition to the five (5) temperature measurements indicated, the ambient air temperature is recorded, asper 7.7.2.


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2 Thermal Stability of Insulated System Test Loop Diagram per 9.0

Ts1

Tc130 cm

(12 in)

Ts2

Tc2

Power

Supply

Ts1

Tc130 cm

(12 in)

Ts2

Tc2

Power

Supply

Power

Supply

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 suggestedthermocouple positioning. In addition to the temperature measurements indicated, the ambient airtemperature is recorded. The distance between connectors and power supply should, at minimum, bethe 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 toprevent thermal influences.


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Annex D(Informative)

Suggested Thermocouple Locations

The locations shown are for illustration purposes only. Other locations may experience highertemperatures. Determination of the highest temperature point should be made and the thermocouples

installed at that point.

1 Multiport Connector Test Setup

Figure D.1


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2 Splice Test Setup

Figure D.2


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Annex E(Informative)

Guarded Circuit

1 DescriptionA guarded circuit is used to eliminate or to minimize the current flow between the insulation andconductor ends, caused by surface leakage currents.

2 Setup

A typical setup to measure insulation resistance is to submerge the test conductor and sample in waterwith both ends of the conductor exposed to air. Next, apply a test voltage between one exposed end ofthe test conductor and the water (which serves as ground). Resistance is calculated by dividing theknown applied voltage by the measured current.

Applying a voltage between the conductor and water causes current to flow. The current may go twoways, from the wire through the insulation to the water and from the exposed wire along the surface ofthe 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 theinsulation near the exposed conductor ends keeping the exposed conductor ends, along with the barewire, out of the water. The guards will capture or collect the current leakage along the insulation before itreaches 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 Source2) I = Current Total; I = ISTRAY+ IL 7) VG= Guard Voltage

3) IG= Guard Current 8) Figure E1, guard should be close to water, (no potentialbetween water and guard), and current measured in water circuit

4) IL= Leakage Current 9) Figure E1, shows VGto water is 0V.

5) ISTRAY= Current along Insulation


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Figure E.2

1) A = Ammeter 6) V = Voltage Source

2) I = Current Total; I = ISTRAY+ IL 7) VG= Guard Voltage

3) IG= Guard Current8) Figure E2, guard should be close to cable core, (no potentialbetween 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


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