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1、BRITISH STANDARD BS 7609:1992 Code of practice for Installation and inspection of uninsulated compression and mechanical connectors for power cables with copper or aluminium conductors Incorporating Amendment No. 1 ICS 29.120.20 Licensed Copy: London South Bank University, London South Bank Universi
2、ty, Fri Dec 08 12:29:29 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 7609:1992 This British Standard, having been prepared under the direction of the Cables and Insulation Standards Policy Committee, was published under the authority of the Standards Board and comes into effect on 15 October 1992 B
3、SI 2006 The following BSI references relate to the work on this standard: Committee reference CIL/20 Draft for comment 91/31861 DC ISBN 0 580 21215 7 Committees responsible for this British Standard The preparation of this British Standard was entrusted by the Cables and Insulation Standards Policy
4、Committee (CIL/-) to Technical Committee CIL/20, upon which the following bodies were represented: Aluminium Federation Association of Consulting Engineers Association of Manufacturers of Domestic Electrical Appliances British Approvals Service for Cables British Cable Makers Confederation British P
5、lastics Federation British Steel Industry British Telecommunications plc Department of the Environment (Property Services Agency) Department of Trade and Industry (Consumer Safety Unit, CA Division) Electricity Association Engineering Equipment and Materials Users Association Institution of Electric
6、al Engineers London Regional Transport The following bodies were also represented in the drafting of the standard, through subcommittees and panels: Beccama (Beama Electrical Cable Connector and Accessories Manufacturers Association) Electrical Contractors Association Electrical Installation Equipme
7、nt Manufacturers Association (BEAMA Ltd.) ERA Technology Ltd. Institution of Lighting Engineers London Underground Ltd. Transmission and Distribution Association (BEAMA Ltd.) Amendments issued since publication Amd. No. DateComments 1644429 September 2006See foreword Licensed Copy: London South Bank
8、 University, London South Bank University, Fri Dec 08 12:29:29 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 7609:1992 BSI 2006i Contents Page Committees responsibleInside front cover Forewordii 1Scope1 2References1 3Definitions1 4Compression connectors1 5Mechanical connectors8 6Bolting of terminal
9、lugs to equipment8 7Tooling9 8Maintenance and certification of tooling9 Annex A (informative) Maintenance, testing and certification of tooling10 Figure 1 Illustrations of compression die sets3 Figure 2 Illustrations of bi-metallic connector3 Figure 3 Examples of correct and incorrect bolted termina
10、tion4 Figure 4 Examples of correct and incorrect compression preparation5 Figure 5 Illustrations of three compression styles in use6 Figure 6 Examples of common compression faults7 Table 1 Recommended torque wrench settings for aluminium and copper terminations9 List of referencesInside back cover L
11、icensed Copy: London South Bank University, London South Bank University, Fri Dec 08 12:29:29 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 7609:1992 ii BSI 2006 Foreword This British Standard has been prepared under the direction of the Cables and Insulation Standards Policy Committee. BS 7609 is i
12、ntended to give guidance to manufacturers and contractors who use compression and mechanical connectors to enable power cables to be terminated using good engineering practice and to provide quality control guidance for the tools which are used to install connectors. As a code of practice, this Brit
13、ish Standard takes the form of guidance and recommendations. It should not be quoted as if it were a specification and particular care should be taken to ensure that claims of compliance are not misleading. Summary of pages This document comprises a front cover, an inside front cover, pages i and ii
14、, pages 1 to 12, an inside back cover and a back cover. This standard has been updated (see copyright date) and may have had amendments incorporated. This will be indicated in the amendment table on the inside front cover. The start and finish of text introduced or altered by Amendment No. 1:2006 is
15、 indicated in the text by tags . Minor editorial changes are not tagged.!“ 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. Lic
16、ensed Copy: London South Bank University, London South Bank University, Fri Dec 08 12:29:29 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 7609:1992 BSI 20061 1 Scope This British Standard recommends methods and procedures applicable for the installation of uninsulated compression and mechanical conn
17、ectors for use on copper or aluminium conductors of insulated cables conforming to BS EN 60228:2005 having a cross-sectional area equal to or greater than 10 mm2for copper and equal to or greater than 16 mm2for aluminium. 2 References 2.1 Normative references BS 7609 incorporates, by reference, prov
18、isions 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, any of these publications apply to this standard only when incorporated
19、 in it by updating or revision. 2.2 Informative references BS 7609 refers 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 inside back cover, but reference should be made to the latest editions.
20、 3 Definitions For the purposes of this British Standard, the following definitions apply. 3.1 connector component or assembly of components designed to accept one or more conductor(s) for the purpose of making an electrical connection 3.2 mechanical connector assembly designed to clamp conductors b
21、y mechanical screw force 3.3 insulation-piercing connector mechanical connector which does not require removal of the conductor insulation to make an electrical connection 3.4 compression connector component designed to make a connection by deformation of the barrel around the conductor NOTEThe term
22、 compression covers the term crimping. 3.5 barrel part of a connector designed to accommodate the conductor 3.6 palm part of a terminal lug formed flat to make a bolted connection to an equipment terminal 3.7 terminal lug connector comprising a palm and a barrel, for connecting a conductor to an equ
23、ipment terminal 4 Compression connectors 4.1 Selection of connectors and associated compression dies Each connector should be clearly identified by a reference on the barrel or palm. This reference should enable the user to ascertain whether the fitting selected is of the correct size and type for t
24、he 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 conductor 4.2.1 General The insulation should be stripped back so that when assembled no insulation can be trapped in the barrel. Ca
25、re 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 conductors Unless otherwise stated by the connector manufacturer, the conduc
26、tor 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 Grade 80 or a stainless steel wire brush; separate brushes should be kept for copper and aluminium. If cloth is employed, a fresh s
27、trip 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 separate the strands of the conductor and th
28、e 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 abrasion. “! Licensed Copy: London South Bank U
29、niversity, London South Bank University, Fri Dec 08 12:29:29 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 7609:1992 2 BSI 2006 To minimize further oxidation the insertion of the conductor into the connector and the subsequent compression should be carried out immediately in accordance with 4.3. NOT
30、EThe 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 en
31、vironmental conditions are anticipated. 4.2.3 Copper conductors Unless 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 recommended f
32、or aluminium conductors (see 4.2.2) but excluding the coating procedure. Separate brushes should be used for copper and for aluminium. 4.3 Compression After cleaning, the conductor should be inserted into the barrel ensuring the palm is square to the equipment terminal thus avoiding excessive twisti
33、ng 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 (see Figure 4) the conductor should protrude slightly at the palm end. Wi
34、th 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
35、and order of compression operations (if multiple) and whether overlapping is necessary or permissible. Care should be taken to ensure the correct connector is chosen for the conductor and the compression tool used is of a type recommended by the manufacturer. 4.4 Inspection of completed compression
36、connection The completed connector should be examined to ensure: a) the correct connector reference relative to conductor size; b) that the correct die set has been used; c) a completed compression is free from excessive flash or burrs, caused by incorrect compression, which are detrimental to the p
37、erformance 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 has been fully inserted. NOTE 1Examples of typical die sets, bolted terminations and good and poo
38、r compression connections are shown in Figure 1 to Figure 6. NOTE 2Reference should be made to the manufacturers instructions to ascertain that the correct die set has been used. Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 12:29:29 GMT+00:00 2006, Uncontroll
39、ed Copy, (c) BSI BS 7609:1992 BSI 20063 Figure 1 Illustrations of compression die sets Figure 2 Illustrations of bi-metallic connector Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 12:29:29 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 7609:1992 4 BSI 2006 Fig
40、ure 3 Examples of correct and incorrect bolted termination Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 12:29:29 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 7609:1992 BSI 20065 Figure 4 Examples of correct and incorrect compression preparation Licensed Copy
41、: London South Bank University, London South Bank University, Fri Dec 08 12:29:29 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 7609:1992 6 BSI 2006 Figure 5 Illustrations of three compression styles in use Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 12:29:2
42、9 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 7609:1992 BSI 20067 Figure 6 Examples of common compression faults Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 12:29:29 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 7609:1992 8 BSI 2006 5 Mechanical connectors
43、 5.1 Identification Each connector should be clearly identified by a reference on one or more component parts. Where 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
44、 correct size and type for the conductor(s) in question. 5.2 Preparation of conductor 5.2.1 General The insulation should 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 insulati
45、on to avoid damaging the conductor strands with the stripping tool. The exposed conductor should be cleaned to remove any particles of the insulation material. 5.2.2 Aluminium conductor Unless otherwise stated by the connector manufacturer, the conductor should be thoroughly abraded both to remove s
46、urface oxide and create a rough surface to ensure good electrical contact. Suitable abrasives are aluminium oxide cloth Grade 80 or 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
47、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 separate the strands of the conductor and the insulation should be protected from damage and
48、particle ingress. For a conductor from MIND cables as much of the compound as possible should be removed from the surface strands 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 b
49、e 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 conditions are anticipated. 5.2.3 Copper conductors Unless there are obvious signs of oxidation or other surface contamination no conductor preparation is normally required. Wh
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