BS 7609-1992+A2-2009 Code of practice for nInstallation and ninspection of nuninsulated ncompression and nmechanical connectors nfor power cables with ncopper or aluminium nconduct.pdf

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1、BRITISH STANDARDCode of practice forInstallation and inspection of uninsulated compression and mechanical connectors for power cables with copper or aluminium conductorsICS 29.120.20BS 7609:1992+A2:2009Licensed Copy: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 13/05/2009 01:48, Uncontrolled Copy, (c) BS

2、IThis British Standard, having been prepared under the directionof the Cables and Insulation Standards Policy Committee, was published underthe authority of the Standards Board and comes intoeffect on15October1992The following BSI references relate to the work on this standard:Committee referenceCIL

3、/20Draft for comment91/31861DCCommittees responsible for this British StandardThe preparation of this British Standard was entrusted by the Cables and Insulation Standards Policy Committee (CIL/-) to Technical CommitteeCIL/20, upon which the following bodies were represented:Aluminium FederationAsso

4、ciation of Consulting EngineersAssociation of Manufacturers of Domestic Electrical AppliancesBritish Approvals Service for CablesBritish Cable Makers ConfederationBritish Plastics FederationBritish Steel IndustryBritish Telecommunications plcDepartment of the Environment (Property Services Agency)De

5、partment of Trade and Industry (Consumer Safety Unit, CA Division)Electricity AssociationEngineering Equipment and Materials Users AssociationInstitution of Electrical EngineersLondon Regional TransportThe following bodies were also represented in the drafting of the standard, through subcommittees

6、and panels:Beccama (Beama Electrical Cable Connector and Accessories Manufacturers Association)Electrical Contractors AssociationElectrical Installation Equipment Manufacturers Association (BEAMA Ltd.)ERA Technology Ltd.Institution of Lighting EngineersLondon Underground Ltd.Transmission and Distrib

7、ution Association (BEAMA Ltd.)Amendments issued since publicationAmd. No. Date Comments16444 29 September 2006 See foreword BSI2008ISBN 978 0 580 63230 3Amendment 31 December 2008 See forewordNo. 2BS7609:1992+A2:2009Licensed Copy: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 13/05/2009 01:48, Uncontrolle

8、d Copy, (c) BSIiContentsPageCommittees responsible Inside front coverForeword ii1 Scope 12 References 13 Definitions 14 Compression connectors 15 Mechanical connectors 86 Bolting of terminal lugs to equipment 87 Tooling 98 Maintenance and certification of tooling 9Annex A (informative) Maintenance,

9、testing and certification of tooling 10Figure 1 Illustrations of compression die sets 3Figure 2 Illustrations of bi-metallic connector 3Figure 3 Examples of correct and incorrect bolted termination 4Figure 4 Examples of correct and incorrect compression preparation 5Figure 5 Illustrations of three c

10、ompression styles in use 6Figure 6 Examples of common compression faults 7Table 1 Recommended torque wrench settings for aluminiumand copper terminations 9List of references Inside back cover BSI 2008BS7609:1992+A2:2009Licensed Copy: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 13/05/2009 01:48, Uncontro

11、lled Copy, (c) BSIiiForewordThis British Standard has been prepared under the direction of the Cables and Insulation Standards Policy Committee.BS7609is intended to give guidance to manufacturers and contractors who use compression and mechanical connectors to enable power cables to be terminated us

12、ing good engineering practice and to provide quality control guidance for the tools which are used to install connectors.As a code of practice, this British Standard takes the form of guidance and recommendations. It should not be quoted as if it were a specification and particular care should be ta

13、ken to ensure that claims of compliance are not misleading.Summary of pages This document comprises a front cover, an inside front cover, pagesi andii, pages1 to12, an inside back cover and a back cover.This standard has been updated (see copyright date) and may have had amendments incorporated. Thi

14、s will be indicated in the amendment table on theinside front cover.This publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application. Compliance with a British Standard cannot confer immunity from legal obligations. BSI 2008BS

15、7609:1992+A2:2009The start and finish of text introduced or altered by Amendments No. 1 and No.2 is indicated in the text by tags !“ and #$.Licensed Copy: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 13/05/2009 01:48, Uncontrolled Copy, (c) BSI11 ScopeThis British Standard recommends methods and procedur

16、es applicable for the installation of uninsulated compression and mechanical connectors for use on copper or aluminium conductors of insulated cables conforming to BSEN 60228:2005 having a cross-sectional area equal to or greater than10mm2 for copper and equal to or greater than16mm2 for aluminium.2

17、 References2.1 Normative referencesBS7609incorporates, by reference, provisions from specific editions of other publications. These normative references are cited at the appropriate points in the text and the publications are listed on the inside back cover. Subsequent amendments to, or revisions of

18、, any of these publications apply to this standard only when incorporated in it by updating or revision.2.2 Informative referencesBS7609refers to other publications that provide information or guidance. Editions of these publications current at the time of issue of this standard are listed on the in

19、side back cover, but reference should be made to the latest editions.3 DefinitionsFor the purposes of this British Standard, the following definitions apply.3.1 connectorcomponent or assembly of components designed to accept one or more conductor(s) for the purpose of making an electrical connection

20、3.2 mechanical connectorassembly designed to clamp conductors by mechanical screw force3.3 insulation-piercing connectormechanical connector which does not require removal of the conductor insulation to make an electrical connection3.4 compression connectorcomponent designed to make a connection by

21、deformation of the barrel around the conductorNOTEThe term compression covers the term crimping.3.5 barrelpart of a connector designed to accommodate the conductor3.6 palmpart of a terminal lug formed flat to make a bolted connection to an equipment terminal3.7 terminal lugconnector comprising a pal

22、m and a barrel, for connecting a conductor to an equipment terminal4 Compression connectors4.1 Selection of connectors and associated compression diesEach connector should be clearly identified by a reference on the barrel or palm. This reference should enable the user to ascertain whether the fitti

23、ng selected is of the correct size and type for the conductor(s) in question; it should also allow the correct die set and compression tool to be selected from the manufacturers recommended list.4.2 Preparation of a conductor4.2.1 GeneralThe insulation should be stripped back so that when assembled

24、no insulation can be trapped in the barrel.Care should be taken whilst stripping the insulation to avoid damaging the conductor strands with the stripping tool. The exposed conductor should be cleaned to remove any particles of the insulation material.4.2.2 Aluminium conductorsUnless otherwise state

25、d by the connector manufacturer, the conductor should be thoroughly abraded both to remove surface oxide and create a rough surface to ensure good electrical contact. Suitable abrasives are aluminium oxide cloth Grade80or a stainless steel wire brush; separate brushes should be kept for copper and a

26、luminium. If cloth is employed, a fresh strip should be used for each connection made and if a wire brush is employed, the brush should be replaced when the wires are no longer sharp (indicated by the tendency for the brush to skate over the surface). During abrasion, care should be taken not to sep

27、arate the strands of the conductor and the insulation should be protected from damage and particle ingress. For a conductor from mass impregated non-draining (MIND) cables as much of the compound as possible should be removed from the surface strands using a suitable degreasing agent prior to abrasi

28、on.“! BSI 2008BS7609:1992+A2:2009Licensed Copy: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 13/05/2009 01:48, Uncontrolled Copy, (c) BSI2 BSI 2008To minimize further oxidation the insertion of the conductor into the connector and the subsequent compression should be carried out immediately in accordance

29、 with 4.3.NOTEThe use of jointing compounds is not generally required where the connection is to be encapsulated to prevent moisture ingress,e.g.under resin or heat shrink materials. However, for connections which may be open to the atmosphere, the manufacturers instructions should be followed where

30、 adverse environmental conditions are anticipated.4.2.3 Copper conductorsUnless there are obvious signs of oxidation or other surface contamination no conductor preparation is normally required.Where the surface appears tarnished, abrade the conductor surface by following the same procedure as recom

31、mended for aluminium conductors (see4.2.2) but excluding the coating procedure.Separate brushes should be used for copper and for aluminium.4.3 CompressionAfter cleaning, the conductor should be inserted into the barrel ensuring the palm is square to the equipment terminal thus avoiding excessive tw

32、isting of the completed termination.NOTEFor shaped stranded conductor and circular barrel connectors pre-rounding dies may be required prior to insertion; refer to manufacturers data for information.In an open ended terminal lug (seeFigure 4) the conductor should protrude slightly at the palm end. W

33、ith a closed ended terminal lug the conductor should be fully inserted as witnessed through the inspection hole (if provided). The connector should be compressed in accordance with the manufacturers instructions with careful attention paid to the positioning of the die head on the barrel, the number

34、 and order of compression operations (ifmultiple) and whether overlapping is necessary or permissible.Care should be taken to ensure the correct connector 4.4 Inspection of completed compression connectionThe completed connector should be examined to ensure:a) the correct connector reference relativ

35、e to conductor size;flash or burrs, caused by incorrect compression, which are detrimental to the performance of the joint;d) that no insulation is trapped in the barrel;e) that excess grease is wiped off the cable insulation and connector;f) that where inspection holes are provided, the conductor h

36、as been fully inserted.NOTE 1Examples of typical die sets, bolted terminations and good and poor compression connections are shown in Figure 1to Figure 6.NOTE 2Reference should be made to the manufacturers instructions to ascertain that the correct die set has been used.of both copper and aluminium

37、connectors thethe connector and die-set should be as specifiedby the manufacturer. The installer should ensurethat the compression tool used is fully compatiblewith the crimp dies and that the dies fully closeduring the crimp operation.c) a completed compression is free from excessive a) For hexagon

38、 and circumferential crimpingb) that the correct die set has been used;b) For indent type crimping of both copper andaluminium connectors the connector, die-setand tooling should be as specified by themanufacturer. Specific attention should be paidto the servicing and calibration of the compressiont

39、ool in order to guarantee the indent dies arecompressed at the specified pressure.is chosen for the conductor and that the correct #$tool and die combination is used in order to achieve the same crimped connection as per the connectorsatisfactory type test.manufacturersBS7609:1992+A2:2009Licensed Co

40、py: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 13/05/2009 01:48, Uncontrolled Copy, (c) BSI3Figure 1 Illustrations of compression die setsFigure 2 Illustrations of bi-metallic connector BSI 2008BS7609:1992+A2:2009Licensed Copy: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 13/05/2009 01:48, Uncontrolled Copy

41、, (c) BSI4Figure 3 Examples of correct and incorrect bolted termination BSI 2008BS7609:1992+A2:2009+Licensed Copy: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 13/05/2009 01:48, Uncontrolled Copy, (c) BSI5Figure 4 Examples of correct and incorrect compression preparation BSI 2008BS7609:1992+A2:2009Licens

42、ed Copy: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 13/05/2009 01:48, Uncontrolled Copy, (c) BSI6 BSI 2008Figure 5 Illustrations of three compression styles in useBS7609:1992+A2:2009Licensed Copy: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 13/05/2009 01:48, Uncontrolled Copy, (c) BSI7Figure 6 Examples of

43、common compression faults BSI 2008BS7609:1992+A2:2009Licensed Copy: Wang Bin, ISO/EXCHANGE CHINA STANDARDS, 13/05/2009 01:48, Uncontrolled Copy, (c) BSI8 BSI 20085 Mechanical connectors5.1 IdentificationEach connector should be clearly identified by a reference on one or more component parts. Where

44、this is impracticable then the reference should be clearly visible either on or within the packaging. This reference should enable the user to confirm that the fitting selected is the correct size and type for the conductor(s) in question.5.2 Preparation of conductor5.2.1 GeneralThe insulation shoul

45、d be stripped back so that when assembled no insulation can be trapped in the barrel (except for insulation-piercing connectors).Care should be taken whilst stripping the insulation to avoid damaging the conductor strands with the stripping tool. The exposed conductor should be cleaned to remove any

46、 particles of the insulation material.5.2.2 Aluminium conductorUnless otherwise stated by the connector manufacturer, the conductor should be thoroughly abraded both to remove surface oxide and create a rough surface to ensure good electrical contact. Suitable abrasives are aluminium oxide cloth Gra

47、de80or a stainless steel wire brush; separate brushes should be kept for copper and aluminium. If cloth is employed, a fresh strip should be used for each connection made and if a wire brush is employed, the brush should be replaced when the wires are no longer sharp (indicated by the tendency for t

48、he brush to skate over the surface). During abrasion, care should be taken not to separate the strands of the conductor and the insulation should be protected from damage and particle ingress. For a conductor from MIND cables as much of the compound as possible should be removed from the surface str

49、ands using a suitable degreasing agent prior to abrasion.To minimize further oxidation, the insertion of the conductor into the connector and the subsequent assembly should be carried out immediately in accordance with 5.3.NOTEThe use of jointing compounds is not generally required where the connection is to be encapsulated to prevent moisture ingress,e.g.under resin or heat shrink materials. However, for connections which may be open to the atmosphere, the manufacturers instructions should be followed where adverse environmental