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SANS 1489-1:2005
ISBN 0-626-
Edition 1
SOUTH AFRICAN NATIONAL STANDARD
Electrical connectors in hazardous locations
Part 1: General requirements for group I and
group II
Published by Standards South Africa
1 dr lategan road groenkloof  private bag x191 pretoria 0001
tel: 012 428 7911 fax: 012 344 1568 international code + 27 12
www.stansa.co.za
 Standards South Africa
SANS 1489-1:2005
Edition 1
Table of changes
Change No.
Date
Scope
Abstract
Specifies general requirements for electrical connectors of a restrained type and bolted type,
(incorporating three power contacts, one pilot contact for electrical interlocking and earth continuity)
primarily intended for use in group I and group II hazardous locations, and is connected to its power
supply by means of an individually screened flexible cable and a collectively or individually steel
armoured cable.
Keywords
adaptors, couplers, electric plugs, electric sockets, electrical connectors, hazardous locations, plugs
(electric), sockets (electric).
Foreword
This South African standard was approved by National Committee StanSA TC 65, Explosion
prevention, in accordance with procedures of Standards South Africa, in compliance with annex 3 of
the WTO/TBT agreement.
Annexes A and B form an integral part of this standard.
Introduction
The prime objective of this standard is to ensure that electrical connectors of similar design and
rating and that are intended to be interconnected are fully compatible and interchangeable,
irrespective of having been produced by different manufacturers.
In South Africa control of hazardous locations is regulated in terms of the Mine Health and Safety
Act, 1996 (Act no. 29 of 1996) by the (Regulator) Chief Inspector of Mines of the Department of
Minerals and Energy; or in terms of the Occupational Health and Safety Act, 1993 (Act no. 85 of
1993) by the (Regulator) Chief Inspector of Occupational Health and Safety of the Department of
Labour, or in terms of the Explosives Act, 1956 (Act no. 26 of 1956) by the (Regulator) Chief
Inspector of Explosives of the Department of Labour.
NOTE The latest available editions of these acts are applicable and should be consulted. This standard forms part of
these acts.
In South Africa, it is required by the Regulator that the test laboratory be an (ATL) approved test
laboratory.
Contents
Page
Abstract
Keywords
Foreword
1 Scope ...............................................................................................................................
2 Normative references .......................................................................................................
3 Definitions and abbreviations ............................................................................................
4 Requirements ...................................................................................................................
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
General ....................................................................................................................
Insulators ..................................................................................................................
Contacts ....................................................................................................................
Earthing ....................................................................................................................
Cable glands .............................................................................................................
Terminals .................................................................................................................
Lock-out facilities for electrical connectors ...............................................................
Mechanical interlock .................................................................................................
Flameproof enclosure ...............................................................................................
5 Marking ..............................................................................................................................
6 Type verifications and methods of tests ............................................................................
7 Routine verifications and methods of tests. ......................................................................
8 Annex A (normative), Batch testing for electrical connectors ...........................................
9 Bibliography .......................................................................................................................
Electrical connectors hazardous locations
Part 1: General requirements for group I and group II
1 Scope
1.1 This standard specifies general requirements for electrical connectors of a restrained type and
bolted type, (incorporating up to three power contacts, at least one pilot contact for electrical
interlocking and earth continuity) primarily intended for use in group I and group II hazardous
locations, and is connected to its power supply by means of a flexible cable (SANS 1520-1 and SANS
1520-2) or a steel armoured cable (SANS 1339).
1.2 Requirements for system voltages (Uo / U) not exceeding 220/380 V, 650/1100 V, 1100/3300 V,
1900/3300 V, 3800/6600 V, 6343/11000 V and 12700/22000 V and 19000/33000 V electrical
connectors are laid down.
1.3 Electrical connectors used in dual voltages, a.c. and d.c. voltage systems are specified in the
relevant parts of SANS 1489.
1.4 In the design, manufacture and/or use of any product specified in this part SANS 1489 cognisance
shall be taken of the requirements of ISO 14000 and ISO 14001.
1.5 These standards cover zone 1, zone 2 and do not include zone 20, zone 21 and zone 22.
1.6 Connections for dedicated intrinsic safety circuits is not covered in any part of SANS 1489.
2 Normative references
The following standards contain provisions which, through reference in this text, constitute provisions
of this standard. All standards are subject to revision and, since any reference to a standard is
deemed to be a reference to the latest edition of that standard, parties to agreements based on this
standard are encouraged to take steps to ensure the use of the most recent editions of the standards
indicated below. Information on currently valid national and international standards can be obtained
from Standards South Africa.
BS 6346, Specification for 600/1000 V and 1900/3300 V armoured electric cables having PVC
insulation
BS EN 61238-1, Compression and mechanical connectors for power cables for rated voltages up to
36 kV (Um = 42 kV) - Part 1: Test methods and requirements
EN 12163, Copper and copper alloys – Rod for general purposes
EN 12164, Copper and copper alloys – Rod for free machining purposes
EN 12167, Copper and copper alloys – Profiles and rectangular bar for general purposes
IEC 60112, Method for the determination of the proof and the comparative tracking indices of solid
insulating materials
IEC 60243-2, Electric strength of insulating materials – Test methods – Part 2: Additional
requirements for tests using direct voltage
ISO 93-1, Textile machinery and accessories – Cylindrical sliver cans – Part 1: Main dimensions
ISO 93-2, Textile machinery and accessories – Cylindrical sliver cans – Part 2: Spring bottoms
4
ISO 4026, Hexagon socket set screws with flat point
ISO 4027, Hexagon socket set screws with cone point
ISO 4028, Hexagon socket set screws with dog point
ISO 4029, Hexagon socket set screws with cup point
SANS 96, Batch sampling and acceptance criteria for explosion protected apparatus
SANS 1339, Electric cables - Cross-linked polyethylene (XLPE) insulated cables for rated voltages
3,8/6,6 kV to 19/33 kV
SANS 1489-21, Electrical connectors in hazardous locations Part 2: Restrained type plugs and
sockets for use in group I hazardous locations
SANS 1489-31, Electrical connectors in hazardous locations Part 3: Bolted type plugs and sockets for
use in group I hazardous locations
SANS 1489-41, Electrical connectors in hazardous locations Part 4: Couplers and adaptors for use in
group I hazardous locations
SANS 1489-51, Electrical connectors in hazardous locations Part 5: Restrained type plugs and
sockets for use in group II hazardous locations
SANS 1489-61, Electrical connectors in hazardous locations Part 6: Bolted type plugs and sockets for
use in group II hazardous locations
SANS 1489-71, Electrical connectors in hazardous locations Part 7: Couplers and adaptors for use in
group II hazardous locations
SANS 1520-1, Flexible electric trailing cables for use in mines – Part 1: Low-voltage (640/1 100 V and
1 900/3 300 V) cables
SANS 1520-2, Flexible electric trailing cables for use in mines – Part 2: High-voltage (3,8/6,6 kV to
19/33 kV) cables
SANS 6291 (SABS SM 1291), Partial discharge measurements on power cables
SANS 6892 (SABS ISO 6892), Metallic materials – Tensile testing at ambient temperature.
SANS 6284-3 (SABS SM 1284-3), Test methods for cross-linked polyethylene (XLPE) insulated
electric cables – Part 3: Tests on finished cable
SANS 10012, The use of light metals in hazardous locations at mines
SANS 60079-0, Electrical apparatus for explosive gas atmospheres – Part 0: General requirements
SANS 60079-1, Electrical apparatus for explosive gas atmospheres – Part 1: Flameproof enclosures
“d”.
SANS 60529, Degrees of protection provided by enclosures (IP code)
1
This standard is under preparation.
SANS 1489-1:2005
Edition 1
3 Definitions and abbreviations
For the purposes of this standard, the following definitions and abbreviations apply:
3.1.1
alternating current
A.C
electric current that reverses direction sinusoidally
3.1.2
acceptable
acceptable to the parties concluding the purchase agreement, but in relation to the inspection and testing
carried out by a test laboratory , acceptable to this test laboratory
3.1.3
adaptor
device used to connect a cable half coupler to apparatus, which can either be separate from or be integral
with the enclosure of the apparatus and which can include live-line indication
3.1.4
ampere
(A)
constant current which, if maintained in two straight parallel conductors of infinite length, of negligible
circular cross-section, and placed 1 m apart in a vacuum, would produce between these conductors a
force equal to 2 x 10-7 newton per meter of length
3.1.5
apparatus interface
interfacing dimensions and equipment mounting details shall be in line with the appropriate drawings of
the relevant parts of SANS 1489
NOTE 1 These dimensions are to be used as the basis for determining the flame path dimensions on the apparatus to
which the socket is attached, as given in SANS 60079-0 and SANS 60079-1 for different sizes and types of flameproof
enclosures.
NOTE 2 Annex C shows an alternative apparatus interface presently in use on 425 A sockets and adaptor flanges which
can be fitted to such an interface to achieve the interface described in this standard, and vice versa.
3.1.6
approved test laboratory
ATL
test laboratory that is accredited by the government-endorsed national accreditation body and appointed
by the approving authority to carry out tests specified in the appropriate standards and to issue IA
certificates for explosion protected apparatus indicating that such apparatus complies with safety and any
other requirements of the approving authority.
3.1.7
approving authority
body legally responsible for the relevant legislation. (See foreword).
3.1.8
cable gland
assembly that mechanically attaches the end of a cable in an electrical connector and locates the cable
securely, ensures good earthing contact between the electrical connector case and the cable armour or
screen, seals off the opening between the case and cable ensuring flameproof and mechanically
integrity. The assembly should be such as to prevent damage to the cable
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3.1.9
cable half coupler
detachable cable sealing box utilizing contact tubes and pins to facilitate ready connection to, or
disconnection from a similar unit or other apparatus
3.1.10
direct current
D.C
electric current that flows in one direction steadily
3.1.11
defective
flameproof electrical connector that fails in one or more respects to comply with the relevant requirements
of this standard
3.1.12
electrical connector
device that consists of two parts that have metal contacts arranged to engage with each other, so forming
a ready means of connecting or disconnecting current-using apparatus to or from the source of electrical
supply
3.1.13
electrical connector back-to-back coupler (coupling unit)
electrical connector that incorporates two electrical connector entries mounted back-to-back, each
providing for the insertion and engagement of an electrical connector
3.1.14
flameproof electrical connector
electrical connector that, when its portions are properly assembled together with the cable attached,
complies with the flameproof requirements of SANS 60079-1 and SANS 60079-0.
3.1.15
hazardous location
location determined by the regulation or the mine’s or plant’s risk assessment, where there might be a
significant risk of igniting gas, dust or vapour.
NOTE For the classification of hazardous locations see SANS 10108.
3.1.16
kilogram
(kg)
equivalent to the weight in a vacuum of one thousand cubic centimetres of pure water at its
maximum density
3.1.17
original equipment manufacturer
OEM
equipment designer and manufacturer
3.1.18
newton
(N)
force which gives to a mass of 1 kilogram an acceleration of 1 meter per second per second
SANS 1489-1:2005
Edition 1
3.1.19
rated service current (RSC)
r.m.s. value of the current that the plug and socket (or a plug and plug coupling unit) can continuously
conduct without exceeding the temperature rise given in 4.7.4.1 and being at least equal to the nominal
rated current
NOTE The rated service current is used to determine the maximum cable conductor size and overall cable diameter
as given in tables 2A and 2B of SANS 1520-1.
3.1.20
restrained electrical connector
electrical connector in which two portions are engaged, retained and disengaged by means of a manually
operated restraining device
3.1.21
routine tests
tests conducted by a manufacturer or repairer on all units, to verify compliance with this standard
3.1.22
scraping earthing contact
device intended to ensure electrical continuity of the earthing connection between different parts of an
electrical connector while engaged and during disengagement
3.1.23
type tests
tests conducted on a prototype, to verify compliance with this standard
3.1.24
volt
(V)
difference of electric potential between two points of a conducting wire carrying a constant current of 1
ampere, when the power dissipated between these points is equal to 1 watt
3.1.25
zone 0
area in which an explosive gas atmosphere is present continuously or for long periods.
3.1.26
zone 1
area in which an explosive gas atmosphere is likely to occur in normal operation.
3.1.27
zone 2
area in which an explosive gas atmosphere is not likely to occur in normal operation and, if it does occur,
is likely to do so only infrequently and will exist for a short period only.
3.1.28
zone 20
area in which combustible dust, as a cloud, is present continuously or frequently, during normal operation,
in sufficient quantity to be capable of producing an explosive concentration of combustible dust mixed
with air or where layers of dust of uncontrollable and excessive thickness can be formed (or both).
3.1.29
zone 21
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SANS 1489-1:2005
Edition 1
area not classified as zone 20 in which combustible dust, as a cloud, is likely to occur during normal
operation, in sufficient quantities to be capable of producing an explosive concentration of combustible
dust mixed with air.
3.1.30
zone 22
area not classified as zone 21 in which combustible dust clouds might occur infrequently, and persist for
only a short period, or in which accumulations or layers of combustible dust might be present under
abnormal conditions and give rise to combustible mixtures of dust in air. Where, following an abnormal
condition, the removal of dust accumulations or layers cannot be assured, the area shall be classified as
zone 21.
3.2 Abbreviations
ATL
ARP
DME
DoL
OEM
IEC
ISO
SANS
StanSA
–
–
–
–
–
–
–
–
–
Approved Test Laboratory
Aanbevole/Recommended Practice
Department of Minerals and Energy
Department of Labour
Original Equipment Manufacturer
International Electrotechnical Commission
International Standards Organization
South African National Standard
Standards South Africa
4 Requirements
4.1 General
4.1.1 In the design, manufacturing or use of any product standard within the relevant parts of SANS 1489,
cognisance shall be taken as to ensure compliance with the requirements of ISO 14000 and
ISO 14001.
4.1.2 Ingress protection
When tested in accordance with SANS 60529, an electrical connector shall have a minimum rating of
IP 65.
4.1.3 Metal components
No part of an electrical connector shall be made of metal that contains more than 10 % (by mass) of
magnesium, aluminium or titanium or any light alloy prohibited by SANS 10012.
4.1.4 Prevention of contact making
4.1.4.1 The OEM shall ensure that the design of an electrical connector of a restrained type shall not be
able to draw power from an electrical connector of a bolted type by the insertion (to any extent) of a
restrained type and vice versa.
4.1.4.2 The OEM shall ensure that electrical connectors of different amperage and voltage shall not be
able to connect in such a way that they can fulfil their intended function.
4.1.5 Component assembly
As far as practicable, the OEM shall ensure that the design of a component shall be such that the
incorrect or unsafe assembly of an electrical connector is eliminated.
SANS 1489-1:2005
Edition 1
4.1.6 Interchangeability
4.1.6.1 The design of an electrical connector shall be such as to allow each insulator to be orientated in
either the 650 V or the 1 100 V mode (dual voltage), for example, with two keyways.
4.1.6.2 The assembly and orientation of the associated pins and tubes shall be in line with the appropriate
figures of the relevant parts of SANS 1489.
4.1.7 Flameproof and mechanical compatibility
4.1.7.1 The OEM shall ensure compliance and compatibility of his electrical connector with other OEM’s
electrical connectors during type testing.
4.1.7.2 This may be achieved by means of dimensional verifications by a test laboratory (see foreword).
4.1.8 Electrical stress relief
Provision shall be made for electrical stress relief of cable terminations for electrical connectors rated
11 kV and higher.
4.2. Insulators
4.2.1 General
Insulators shall be free from voids, cracks and deleterious inclusions and will have maximum water
absorption as per table 23.
4.2.2 Heat resistance
When an insulator is tested in accordance with the relevant type tests, there shall be no form of surface
cracking or scaling and the largest dimension of the insulator shall not have changed by more than 0,2 %.
4.2.3 Earth screen
The insulator whether for plug or socket shall incorporate a solid metal earth screen between each power
phase, and a common between power phases and all auxiliaries. The earth screen shall extend as near
to the ends of the insulator as is practicable, and the radial length of each fin shall be such that the radial
distance between the tip of the fin and the outer surface of the insulator does not exceed 10 mm.
The earth screen shall be moulded integrally with the insulator so that the fins are located midway
between the respective contact housings.
There shall be visible indication at the front of the insulator that a separator has been incorporated.
Provision shall be made for earth-bonding the separator to the body of the plug or socket or plug-coupling
unit.
4.3 Contacts
Each electrical connector shall have:
a) for a.c. three phase, at least three power contacts and at least one pilot contact (contact tube or
contact pin as may be appropriate),
b) for a.c single phase, at least two power contacts, and
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SANS 1489-1:2005
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c) for d.c. at least two power contacts and at least one pilot contact.
Where applicable the principle of “last make first break” shall apply to the pilot contact with reference to
the phase contact.
(Where applicable the insertion sequence shall be: scrapping earth, phase contact, pilot contact) and
(the reverse sequence shall be: pilot contact, phase contact, scrapping earth).
4.4 Earthing
Electrical connectors shall have earthing terminals that are capable of securely accommodating
conductors of nominal cross-sectional area as per cable manufacturer’s specification. Additional terminals
shall be provided to securely accommodate any and/or metal screens in the associated cables to safely
cater for short circuit currents and earth fault currents due to earthing techniques.
Earth integrity and continuity shall be maintained through cross bonding or any other method as
described by the OEM.
4.5 Cable glands
4.5.1 The cable gland shall be capable of accommodating both individually and collectively screened
flexible cables, and any special cable requirement shall comply with the relevant specification for that
glanding arrangement.
4.6 Terminals
4.6.1 General
4.6.1.1 The terminals of an electrical connector shall be crimped or soldered connections. All connections
shall be designed to resist loosening due to vibration or temperature variation.
The use of grub screws is not a recommended practice.
4.6.2 Crimped connections
The use of hexagon crimping as method of crimp termination is recommended and shall comply with the
manufacturer's recommendations.
4.6.3 Soldered connections
Soldered connections shall comply with the manufacturer's recommendations.
4.6.4 Test methods and requirements
Test methods and requirements for crimped and soldered connections shall comply with the BS EN
61238-1.
4.6.5 Conductor insertion depth
Conductor insertion depth shall provide for a conductor insertion depth of not less than that shown in
Table 1.
SANS 1489-1:2005
Edition 1
Table 1 — Conductor insertion depth
Current
Main conductor core
Pilot/Auxiliary core
Rating
Insertion depth
Insertion depth
(A)
mm
mm
30
15
10
50/100
15
10
60
15
10
120
20
10
200/250
25
10
300
25
10
425/430
25
10
500
40
10
4.7 Lock-out facilities for electrical connectors
Lockout facilities for electrical connectors shall be in line with the appropriate figures of the relevant parts
of SANS 1489.
4.8 Mechanical interlock
4.8.1 A mechanical interlock shall be in line with the appropriate figures of the relevant parts of SANS
1489.
4.8.2 When associated with a circuit breaker, switch or disconnector, an electrical connector may be
provided with a mechanical interlock to ensure that the electrical connector cannot be inserted or
withdrawn without such circuit breaker, switch or disconnector first being opened. Any such interlocking
device should be so arranged that interchangeability of electrical connectors of different makes is still
possible.
4.8.3 Quick release device
Any quick release device shall comply with 4.3 and shall comply with the relevant statutory health and
safety requirements (see foreword).
4.9 Flameproof enclosure
4.9.1 Electrical connectors shall comply with the relevant requirements for group I electrical apparatus of
SANS 60079-0 and SANS 60079-1 and shall comply with the relevant requirements for enclosures of
volume exceeding 2 ℓ.
4.9.2 An electrical connector shall be constructed and mounted so that they do not alter the flameproof
properties of the enclosure on which they are mounted, even when the two parts of the electrical
connector are separated
5 Marking
Electrical connectors shall bear the following information in legible and indelible marking:
12
SANS 1489-1:2005
Edition 1
a) the manufacturer's name or trademark;
b) the manufacturer's type designation;
c) the nominal current rating, the rated service current and the voltages;
d) the appropriate explosion protection, in accordance with SANS 60079-1 and SANS 60079-0 (for
example, "Ex d I"); shall include serial numbers
e) in the case of an electrical connector, a warning on the electrical connector that the supply be isolated
from the electrical connector before they are disconnected;
f) where applicable, the degree of protection provided, in accordance with SANS 60529.
g) serial numbers
h) the symbol for each type of protection used:
-
“o” : oil immersion
-
“p” : pressurization
-
“q” : powder filling
-
“d” : flameproof enclosure
-
“e” : increased safety
-
“ia” : intrinsic safety, category “ia”
-
“ib” : intrinsic safety, category “ib”
-
“m” : encapsulation
6. Type verifications and methods of tests
6.1 All type testing shall be carried out on one connector system only.
6.2 The following table represents the type testing that is required for the various sections within this
standard. Details of each specific test and required results can be found in the relevant sections
pertaining to each product.
SANS 1489-1:2005
Edition 1
Table 2.A – Type tests for A.C. electrical connectors
Type tests
Part 2:
Restrained
plugs and
sockets for
group I
Part 3: Bolted
plugs and
sockets for
group I
Part4: Couplers
and adaptors for
group I
Part 5:
Restrained
plugs and
sockets for
group II
Part 6: Bolted
plugs and
sockets for
group II
Part 7: Couplers
and adaptors for
group II
1
Mechanical endurance






2
Temperature rise






3
Voltage withstand






4
Rated short-term current






5
Impulse voltage
N/A
N/A

N/A
N/A

6
Partial discharge






7
Interchangeability






8
Contact tube






9
Contact pin






10
Scrapping earth contact


N/A


N/A
11
Insulation material






12
Degree of protection






Tensile strength of
materials
Tensile load on the
gland












15
Drop
N/A
N/A

N/A
N/A

16
Flameproof






17
Earth screen






13
14
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SANS 1489-1:2005
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Table 2.B - Type test for D.C. electrical connectors
Type tests
Part 2:
Restrained
plugs and
sockets for
group I
Part 3: Bolted
plugs and
sockets for
group I
Part 5:
Restrained
plugs and
sockets for
group II
Part 6: Bolted
plugs and
sockets for
group II
1
Mechanical endurance




2
Temperature rise




3
Voltage withstand




4
Rated short-term current




5
Interchangeability




6
Contact tube




7
Contact pin




8
Scrapping earth contact

N/A

N/A
9
Insulation material




10
Degree of protection




11
Tensile strength of
materials




12
Tensile load on gland




13
Flameproof




6.3 Mechanical endurance test
6.3.1 General
This test shall be performed before the temperature rise test in 6.4
6.3.2 Apparatus
Test rig that alternately engages and disengages a male contact from the female contact in cycles at a
rate of approximately 10 cycles per minute. The test rig may move either the male contact unit or the
female contact unit while holding the other stationary. For connectors not incorporating an earth screen
with scrapping earth contact, only the contacts and insulator assembly need to be mounted in the test rig.
6.3.3 Test specimen
Remove the restraining devices as necessary, to allow rapid engagement and disengagement. Ensure
that the assembly is dry, clean and free from any lubricant on the contact surfaces.
6.3.4 Test procedure
a) Mount the connector or contacts and the insulator assembly into the test rig.
SANS 1489-1:2005
Edition 1
b) Using a minimum of a 5 decimal place ohmmeter, and with the male and female contacts engaged
individually, measure the contact resistance of each phase across the male and female contacts and
note three values on the test report as contact resistance prior to engagement or disengagement test.
c) Carry out 500 cycles of engagement and disengagement.
d) Using a minimum of a 5 decimal place Ohmmeter, and with the male and female contacts engaged
individually, measure the contact resistance of each phase across the male and female contacts and
note three values on the test report as contact resistance after to engagement or disengagement test.
e) The male and female contacts are deemed to have passed the test if the difference between the test
carried out in 6.3.4(b) and the test carried out in 6.3.4d) does not exceed a value of + 5 % of the
values obtained in the test of 6.3.4(b).
6.3.5 Compliance
Perform a resistance test before mechanical endurance, perform the mechanical endurance test and then
re-perform the resistance test, allowing max of + 5 % deviation from the initial resistance test conducted
before the mechanical endurance test. This test shall be conducted on all 3 phases.
6.4 Temperature rise test (test 1 at rated service current) (test 2 at rated duty cycle)
6.4.1 General
This test shall be carried out as soon as possible after the mechanical endurance test in 6.3.
The test shall be carried out using an a.c. (50Hz) voltage source and will be applicable to both a.c. and
d.c. rated electrical connectors.
6.4.2 Apparatus
a) The power supply shall be capable of supplying twice the alternating rated service current of the
electrical connector.
b) Temperature sensors shall consist of seven thermocouples, and monitor equipment that is capable of
recording the temperatures of the thermocouples.
c) The non-metal enclosure shall be of a volume not exceeding 0,05 m3.
d) A flexible cable with cores of the smallest nominal cross-sectional area capable of carrying a current
corresponding to the rated service current of the electrical connector (combination) shall be used.
6.4.3 Test procedure
NOTE The test is carried out in draught-free conditions at an ambient temperature of 25 °C ± 5 °C.
a) Mount the electrical connector on the outside of the enclosure, and attach three cores of the cable of
length 1,5 m to the power terminals.
b) Attach a 3 m length of the cable (see 6.4.2d)) to the plug as intended by the manufacturer. If screws
are used, secure the conductors in the terminals by this means only.
c) Position the thermocouples as follows:
1)
Attach one thermocouple to the terminal of each power contact pin and to each power contact
tube, adjacent to the flexible cable conductor.
16
SANS 1489-1:2005
Edition 1
2)
Insert the remaining thermocouple into one of the cores of the cable, 1,5 m from the terminals of
the contact tubes. Introduce the thermocouple through a small hole bored in the cable sheath and
insulation.
d) Engage the electrical connector fully, connect to the power supply and apply an alternating current as
follows:
Test 1: Apply the appropriate rated service current. Monitor the temperature of each thermocouple until
the rate of temperature variation does not exceed 1 K/h.
Test 2: Subject the assembly to the rated duty cycle as per table 3. Monitor the temperature of each
thermocouple until the rate of temperature variation does not exceed 1 K/h
e) Record the initial and final temperatures and check for compliance with the relevant requirements of
6.4
f) Apply the current rating as per table 3.
Table 3 – Rated duty cycle for A.C. and D.C.
Percentage of
Current rating
Time
200%
0.5 min
150%
0.5 min
100%
6 min
54%
3 min
6.4.4 Compliance:
When an electrical connector (assembly) is tested at the rated service current in accordance with 6.4:
a) the highest measured temperature within the electrical connector shall not exceed by more than 10 K
the temperature reached by the cable conductor;
b) the highest measured temperature rise within the electrical connector shall not in any instance exceed
65 K above ambient temperature (see the note to 6.4.3); and
c) the highest measured temperature rise on the external surface of the electrical connector shall not
exceed 35 K above ambient temperature.
6.5 Voltage withstand
6.5.1 General
The test report shall include the actual figures for the applied voltage and the current drawn while the
voltage was applied as well as any deviations of voltage and/or current experienced during the duration of
the test.
SANS 1489-1:2005
Edition 1
6.5.2 Apparatus
The power supply shall be adjustable and capable of supplying a 50 Hz alternating r.m.s. voltage to the
required level of testing as per table 4.
6.5.3 Test procedure
6.5.3.1 Test procedure for power contacts
a)
With the other power and pilot contact pin(s) or tube(s) and the screen bonded to the casing, connect
the power supply between one contact pin or contact tube and the casing of electrical connectors.
b)
Increase the test voltage from 0 V to maximum voltage within 10 s. Maintain maximum voltage level
for 1 min.
c)
Reduce the voltage to 0 as rapidly as possible.
d)
Repeat for each remaining power contact pin and tube.
6.5.3.2 Test procedure for pilot contacts
a)
With all the power contact pin(s) or tube(s) and the screen bonded to the casing, connect the power
supply between the pilot contact pin or contact tube and the casing of the electrical connector.
b)
Increase the test voltage from 0 volts to maximum of 2 000 V within 10 s. Maintain this level for 1
min.
c)
Reduce voltage to 0 as rapidly as possible.
Table 4 – Voltage withstand
System Maximum
Test voltage
Voltages Operating
(phase to ground)
(KV)
Voltages
Cable Type
(KV)
RUBBER.
X.L.P.E.
1,1
1,2
2,5
3,3
3,6
5,5
6,6
7,2
8,0
13,0
11
12
13,0
22,0
22
24
25,0
44,0
33
36
38,0
66,0
1 min
6.5.4 Compliance
a) When an electrical connector assembly is tested according to the above test there shall be no sign of
electrical breakdown or tracking.
b) The test report shall include the actual figures for the applied voltage and the current drawn while the
voltage was applied as well as any deviations of voltage and/or current experienced during the duration of
18
SANS 1489-1:2005
Edition 1
the test.
6.6 Rated short-term current
6.6.1 Apparatus
The power supply shall be capable of supplying symmetrical and asymmetrical 3 phase r.m.s alternating
current to the levels as stipulated in relevant tables 5, 6, 7, 8, 9 and 10.
6.6.2 Test procedure
6.6.2.1 Symmetrical Test (to be conducted first)
Connect the electrical connector assembly to the power supply and pass the specified current for 1 sec.
To be conducted on A.C connectors only.
6.6.2.2 Asymmetrical Test (to be conducted after the symmetrical test in 6.6.2.1)
Connect the electrical connector assembly to the power supply and pass the specified current for 200
milliseconds. To be conducted on A.C connectors only.
6.6.2.3 Test on D.C connectors
Apply an A.C current as listed under 6.6.2.1 (symmetrical test) (see Table 5) for a duration of 200
milliseconds only.
6.6.3 Compliance
6.6.3.1 General
Light welding of the contacts is permissible, provided that they can be separated by normal means. If any
burning is visible, the assembly shall, without any reconditioning, still comply with the requirements of
6.4.4.
6.6.3.2 Compliance for symmetrical test
Check that there is no heat discoloration of the contacts or the insulators.
6.6.3.3 Compliance for asymmetrical test
Check assembly once tested for no evidence of mechanical breakdown of the contacts or insulators.
Table 5 – Rated short-term current for 1 100 V
1 200 V Restrained and Bolted Plugs and Sockets.
RUBBER CABLES TO SANS 1520-1 (1 100 V)
Rated Service
Cable size
Short-circuit current
Current (A)
(mm2)
Symmetric (1 s)
Asymmetric (200 ms)
30
4
0,49
0,98
50 / 100
16
2,0
4,0
60
6
0,73
1,46
120
25
3,1
6,2
200
50
6,1
12,2
250
70
8,5
17,0
300
95
11,6
23,2
425/430
150
18,3
36,6
SANS 1489-1:2005
Edition 1
Table 6 – Rated short-term current for 3 300 V
3 600 V Restrained and Bolted Plugs and Sockets.
RUBBER CABLES TO SANS 1520-1 (3 300 V)
Rated Service
Cable size
Current (A)
(mm2)
Short-circuit current
Symmetric (1 s)
Asymmetric (200 ms)
300
95
11,6
23,2
500
240
29,0
58,0
Table 7 – Rated short-term current for rubber cables (half couplers and adaptors)
Half Couplers and Adaptors
RUBBER CABLES TO SANS 1520-2
Rated Service
Cable size
Short-circuit current
Current (A)
(mm2)
Symmetric (1 s)
Asymmetric (200 ms)
300
150
18,3
36,6
400
240
29,28
58,56
Table 8 – Rated short-term current for X.L.P.E cables (half couplers and adaptors)
Half Couplers and Adaptors.
X.L.P.E. CABLES TO SANS 1339
Rated Service
Cable Size
Short-circuit current
Current (A)
(mm2)
Symmetric (1s)
Asymmetric (1s)
300
95
13,6
27,2
400
150
22,0
44,0
Table 9 – Rated short-term current for rubber cables (Non-flameproof connectors)
Non-Flameproof Connectors
RUBBER CABLES SANS 1520-2
Rated Service
Cable Size
Short-circuit current
Current (A)
(mm2)
Symmetric (1s)
Asymmetric (200 ms)
200
70
8.54
17.08
400
240
29.28
58.56
20
SANS 1489-1:2005
Edition 1
Table 10 – Rated short-term current for X.L.P.E cables (Non-flameproof connectors)
Non-Flameproof Connectors
X.L.P.E CABLES SANS 1339
Cable Size
Short-circuit current
Symmetric (1s)
Asymmetric (200 ms)
(mm2)
50
7
14
150
22
44
185
27.4
54.8
Rated Service
Current (A)
200
400
500
6.7. Impulse voltage test
6.7.1 General
This test is only to be conducted on electrical connectors that have an XLPE capability.
6.7.2 Apparatus, test procedure and compliance
The apparatus, test procedure and compliance shall be in accordance with SANS 6284-3.
Table 11 – Impulse voltage test for X.L.P.E cables
System
Voltage (KV)
Maximum
Operating
Voltage (KV)
X.L.P.E
1,1
1,2
3,3
3,6
6,6
7,2
75
11
12
95
22
24
150
33
36
200
6.8 Partial discharge
6.8.1 General
The apparatus, test procedure and compliance shall be in accordance with the relevant parts of
SANS 6291.
SANS 1489-1:2005
Edition 1
Table 12 – Partial discharge for rubber and X.L.P.E cables
System
Voltage (kV)
Maximum
Operating
Voltage (kV)
TEST VOLTAGE
PHASE TO GROUND
CABLE TYPE
RUBBER
X.L.P.E
1,1
1,2
3,3
3,6
2.8
6,6
7,2
5.5
6.6
11
12
9.5
11
22
24
19
22
33
36
28.5
33
SANS 6291
6.9. Interchangeability test
6.7.1 General
Drawings for all relevant electrical connectors are provided in the relevant parts of SANS 1489. The
product is deemed to be interchangeable if all drawing dimensions are complied with.
6.10 Contact tube test
6.10.1 Apparatus
a) Test mandrels shall have a surface roughness value (Ra) not exceeding 1,6 µm, that are of diameter as
given in table 13 to 17 where relevant, and of a length exceeding the full depth permissible by the
engaging portion of the plug casing (barrel).
b) Prior to testing all contacts shall be firstly conditioned using the test mandrel as specified for the
relevant test.
c) Contact tubes (power) shall comply with the dimensions given in Annexure B.
Contact tubes (power) with integral cable connections and/or contact tubes (power) with separate cable
connections shall comply with the following standard BS 2874 Type C101 (Copper) or BS 2874 CZ121
(Brass).
d) Contact tube (earth) shall comply with the dimensions given in Annexure B
Contact tubes (earth) with integral cable connections and/or contact tubes (power) with separate cable
connections shall comply with the following standard BS 2874 Type C101 (Copper) or BS 2874 CZ121
(Brass).
6.10.2 Test procedure
The tests shall be performed in accordance with tables 13 to 17, where relevant:
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SANS 1489-1:2005
Edition 1
Table 13 – 1 200 V Restrained and bolted plugs and sockets
1 200 V Restrained and Bolted: Plugs and Sockets
Rated Service
Current Tube
Diameter of mandrel
Phase (mm)
Depth of engagement
Pilot (mm)
Phase (mm)
Pilot (mm)
(A)
Min
Max
Min
Max
Min
Max
Min
Max
30
7,89
7,91
9,47
9,49
14
15
14
15
50 / 100
7,89
7,91
9,47
9,49
14
15
14
15
60
6,28
6,30
6,28
6,30
15
16
10
11
120
8
8.05
7.95
8.05
11.5
12.5
4.5
5.5
200 / 250
12,61
12,63
9,44
9,46
25
26
9,5
11
300
15,77
15,79
9,44
9,46
34
35
9,5
11
425/430
18,94
18,96
9,44
9,46
34
35
9,5
11
Table 14 – Interference dimensions for 3 600 V restrained and bolted plugs and sockets
3 600 Volts Restrained and Bolted, Plugs and Sockets
Diameter of mandrel
Rated Service
Current Tube
(A)
Phase (mm)
Depth of engagement
Pilot (mm)
Phase (mm)
Pilot (mm)
Min
Max
Min
Max
Min
Max
Min
Max
300
15,77
15,79
9,44
9,46
34
35
9,5
11
500
19,86
19,90
9,44
9,46
34
35
9,5
11
Table 15 – Interference dimensions for 3 600 / 7 200 V half coupler and adaptors
3 600/ 7 200 V Half Couplers and Adaptors
Diameter of mandrel
Rated Service
Current (Tube)
(A)
Phase (mm)
Depth of engagement
Pilot (mm)
Phase (mm)
Pilot (mm)
Min
Max
Min
Max
Min
Max
Min
Max
300
15,82
15,84
–
–
29
30
–
–
400
17,87
17,89
–
–
29
30
–
–
SANS 1489-1:2005
Edition 1
Table 16 – Interference dimensions for 12 000/24 000 volts half coupler and adaptors
12000 / 24 000 Volts Half Couplers and Adaptors
Diameter of mandrel
Rated Service
Current (Tube)
(A)
Depth of engagement
Phase (mm)
Pilot (mm)
Phase (mm)
Pilot (mm)
Min
Max
Min
Max
Min
Max
Min
Max
300
15,77
15,79
9,47
9,49
24
25
8
9
400
18,94
18,96
9,47
9,49
24
25
8
9
Table 17 – Parameters for contact pressure testing of contact tubes and or pins
Non-Flameproof Connectors
Rated Service
Diameter of mandrel
Current Tube
Depth of engagement
Phase (mm)
Earth (mm)
Pilot (mm)
Phase (mm)
Earth (mm)
Pilot (mm)
Min
Min
Min
Max
Min
Max
Min
Max
Min
Max
(200) Mandrel
11,93 11,95 11,93 11,95 4,15
4,17
25
26
22
23
21
22
(400) Mandrel
18,94 18,96 18,94 18,96 9,44
9,96
34
35
39
40
10
11
4,15
4,17
–
–
–
–
21
22
–
–
39
40
49
50
–
–
(A)
–
(500) Mandrel
(500) Tube
Max
–
–
Max
–
25,45 25,47 25,45 25,47
6.11 Pilot and ancillary contact
6.11.1 Contact tube (pilot/ancillary) shall comply with the dimensions given in Annexure B.
Contact tubes (pilot/ancillary) with integral cable connections and/or contact tubes (power) with separate
cable connections shall comply with the following standard BS 2874 Type C101 (Copper) or BS 2874
CZ121 (Brass).
6.11.2 When a contact tube is tested in accordance with the above, the axial force necessary to withdraw
the mandrel shall in accordance with table 18:
6.12 Power contact test
6.12.1 Apparatus
a) Test mandrels shall that have a surface roughness value (Ra) not exceeding 1,6 µm, that are of
diameter as given in table 20, and of a length exceeding the full depth permissible by the engaging
portion of the plug casing (barrel).
b) Prior to testing all pins shall be firstly conditioned using the test mandrel as specified for the relevant
test.
c) Contact pins (power) shall comply with the dimensions given in Annexure B.
24
SANS 1489-1:2005
Edition 1
Contact pins (power) with integral cable connections and/or contact tubes (power) with separate cable
connections shall comply with the following standard BS 2874 Type C101 (Copper) or BS 2874 CZ121
(Brass).
d) Contact pins (earth) shall comply with the dimensions given in Annexure B.
Contact pins (earth) with integral cable connections and/or contact tubes (power) with separate cable
connections shall comply with the following standard BS 2874 Type C101 (Copper) or BS 2874 CZ121
(Brass).
e) Pilot and ancillary contact
Pilot and ancillary contact pins shall comply with the dimensions given in Annexure B.
Pilot and ancillary contact pins with integral cable connections or contact pins (power) (or both) with
separate cable connections shall be in accordance with BS 2874 Type C101 (Copper) or BS 2874 CZ121
(Brass).
f) Contact pins shall be tested, and shall be in accordance with the requirements of tables 13 to 17, listed
in 6.10.
Table 18 – Axial forces of contacts
Rated Service
Current
(A)
30
50 / 100
60
120
200 / 250
300
400 / 425 / 430
500
Power Contact
Force
To Withdraw (Kg)
> 3,47
> 3,47
> 2,24
> 4.59
> 4,59
> 6,12
> 7,14
> 7,65
Pilot Contact
Force
To Withdraw (Kg)
> 2,04
> 2,04
>2.24
>2.04
> 2,04
> 2,04
> 2,04
> 2,04
Note: These requirements are based on contact tubes and or pins being made from
brass or copper that have three or more longitudinal cuts with the segments being
maintained under pressure by an acceptable method when mated with there
respective contact tube or pin. Alternative methods such as " Lambands " may be
employed between a contact tube or contact pin to perform the same function.
6.13. Scraping earth contact test
6.13.1 Apparatus
6.13.1.1 Test mandrels, that have a surface roughness value (Ra) not exceeding 1,6 µm, that are of
diameter as given in table 19, and of a length exceeding the full depth permissible by the engaging
portion of the plug casing (barrel).
6.13.1.2 Means of measuring the force required to insert and to withdraw the mandrel from a socket
casing, to an accuracy of 1 N or better.
SANS 1489-1:2005
Edition 1
Table 19 – Earth interference dimensions for 1 100 V connectors
1 100 V Maximum rating
Rated service current of
the socket (A)
Diameter of mandrel (mm)
Min
57.15
57.15
58.70
57.92
71.4
92
30
50/100
60
120
200/250
300/425/430
Max
57.17
57.17
58.80
57.94
71.42
92.02
Table 20 - Earth interference dimensions for 3 600 volts connectors
3 600 V Maximum rating
Rated service current of
the socket (A)
Diameter of mandrel (mm)
Min
Max
300
94,96
94,98
500
94,96
94,98
6.13.2 Test procedure
a) Insert mandrel into the socket that contains the scraping earth contact. Withdraw the mandrel slowly
and in each case determine the maximum force exerted and check for compliance with tables 21 and 22.
Table 21 – Axial force (kg) earth scrapers (1 200 V)
1 200 V Maximum rating
Rated service current of the socket
(A)
Force to withdrawal
(kg)
30
> 3.65
50 / 100
> 3.65
60
> 4.50
120
> 4.59
200 / 250
> 4.59
300 / 425 / 430
> 5.88
26
SANS 1489-1:2005
Edition 1
Table 22 - Axial force (kg) earth scrapers (3 600 V)
3 600 V Maximum rating
Rated service current of the socket
(A)
Force to withdrawal
(kg)
300
> 6,07
500
> 6,07
6.14 Insulation material test
6.14.1 Test procedure
a) Use the test method given in column 2 of table 23 appropriate to the property given in column 1 and
check for compliance with the relevant requirements of 4.2.1.
b) In the case of test specimens to be used for determining water absorption and the comparative tracking
index, machine at least 0,5 mm from all the surfaces of the specimens and finish the surfaces smoothly
with fine glass paper.
6.15 Heat resistance test
6.15.1 General
Insulators shall be free from voids, cracks and deleterious inclusions.
6.15.2 Test procedure on the insulator
Subject the insulator to a temperature of 120 °C± 5 °C for a period of 24 h. Allow the insulator to cool,
examine it visually, and check for compliance with 4.2.2.
6.15.3 Compliance
6.15.2.1 Insulator
The insulation shall be tested using one of the following methods:
Method A
For insulating material not forming part of a flameproof path:
a) When tested in accordance with 6.14 the material used for insulating the contact tubes and pins of a
connector shall comply with the requirements given in table 23.
b) When an insulator is tested in accordance with 6.15.2, there shall be no form of surface cracking or
scaling and the relevant dimensions if applicable shall not have changed by more than 0,2 %.
Method B
a) For insulating material forming part of a flameproof path:
b) The insulating material shall be tested in accordance with the relevant sections of SANS 60079-1.
SANS 1489-1:2005
Edition 1
Table 23 – Insulation materials
Property
Requirement
Test method
Electrical strength at 90 centigrade (Kv), (mm),
minimum
10
IEC 60243-2
Volume resistivity (Log 10 cm) minimum
13
ISO 93-1
ISO 93-2
400
IEC 60112
Comparative tracking Index. (V), minimum
Water absorption After 24 hours immersed in
water at 23 Centigrade, mg, per Kg, maximum
Maximum operating voltage (V)
1500
3600
7200
12000
24000
36000
50
32
23.5
17.5
12.5
10
6.16 Degree of Protection
6.16.1 Ingress protection
When tested, a plug and socket or a plug and plug coupler unit assembly or a socket and closure cap or a
half coupler and adaptor or a half coupler and closure cap or an adaptor and closure cap, shall have a
rating of at least IP 65.
6.17 Tensile strength of materials
6.17.1 Test procedure
The test procedure shall be in accordance with SANS 6892.
6.17.2 Compliance
a) The engaging portion of the electrical connector casing that protects the contact tubes shall be of metal
of tensile strength, determined in accordance with 6.17.1, of at least 450 MPa.
b) The remaining part of the casing shall be of an acceptable metal that has a tensile strength of at least
225 MPa.
c) The electrical connector casing shall be of an acceptable metal that has a tensile strength, determined
in accordance with 6.17.1, of at least 225 MPa.
28
SANS 1489-1:2005
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6.18 Tensile load on the gland
The test requirement for a gland shall be in accordance with the gland requirements in SANS 60079-0.
6.19 Drop Test
6.19.1 Test procedure for plugs and sockets
The test shall be in accordance with the drop test in SANS 60079-0.
6.19.2 Procedure for couplers and adaptors
Fit the electrical connector to one end of a 3,5 m length of three-core stranded copper wire armoured
cable conforming to SANS 1339, of voltage rating to suit cable and the maximum cross-sectional area
which the connector will accommodate. Using two cable cleats, anchor the other end of the cable
horizontally to a fixed structure positioned 2 m above a concrete surface. The length of free cable
between the electrical connector and the nearest cleat shall be 3 m. Support the electrical connector at
the height of the structure with the cable horizontal, then allow it to drop onto concrete, so that it falls in an
arc of 3 m radius through a vertical height of 2 m. Slacken the cleats, rotate the cable through 90º and
retighten the cleats. Repeat the test, carrying out four in total, rotating the cable through 90º in the same
direction for each repeat test as described. Release the assembly. Longitudinally section the electrical
connector along its centre line and through all points of impact.
6.20 Flameproof Tests
6.20.1 General
All flameproof testing as required on this equipment shall be in accordance with the relevant tests as
required in SANS 60079-0 and SANS 60079-1.
6.21 Earth screen test
6.21.1 Earth fault restrictions up to 2,5 A
6.21.1.1 Test procedure
Perform a temperature rise test by applying a current of 5 A at a frequency of 50 Hz for a duration of 5 s.
6.21.1.2 Compliance
The test shall be deemed successful if the temperature does not exceed 50 K.
6.21.2 Earth fault restrictions above 2,5 A
6.21.2.1 Test procedure
Perform a temperature rise test by applying a current of 500 A at a frequency of 50 Hz for a duration of
5 s.
6.21.2.2 Compliance
The test shall be deemed successful if the temperature does not exceed 50 K.
SANS 1489-1:2005
Edition 1
7 Routine verifications and methods of tests
7.1 General procedure
All routine tests listed in table 24 shall be done in accordance with the relevant type testing procedure
described in clause 6.
Table 24 – Routine tests for electrical connectors
Routine Tests
Part 2
Restrained
Plugs &
Sockets
Group I
Part 5
Part 3 Bolted
Part 4
Restrained
Plugs &
Couplers
Plugs &
Sockets
& Adaptors
Sockets
Group I
Group I
Group II
Part 6
Bolted
Plugs &
Sockets
Group II
Part 7
Couplers
& Adaptors
Group II
1
Voltage
Withstand
or High Voltage






2
Contact Tube Test






3
Contact Pin Test






4
Earth Scraper




N/A
N/A
30
SANS 1489-1:2005
Edition 1
Annex A
(informative)
Batch testing for electrical connectors
A.1
For batch testing, see SANS 96.
Bibliography
SANS 10108, The classification of hazardous locations and the selection of apparatus for use in such
locations
SANS 60079-1:1990, Electrical apparatus for explosive gas atmospheres – Part 1: Construction and
verification test of flameproof enclosures of electrical apparatus.
© Standards South Africa