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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 6 SANS 1489-1:2005 Edition 1 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 8 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 10 SANS 1489-1:2005 Edition 1 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 14 SANS 1489-1:2005 Edition 1 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: 22 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 Edition 1 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