BS 7609-1992+A2-2009 使用铜或铝导线的电力电缆用未绝缘压接或机械连接器的安装和检验的实施规程.pdf

BRITISH STANDARD Code of practice for Installation and inspection of uninsulated compression and mechanical connectors for power cables with copper or aluminium conductors ICS 29.120.20 BS 7609:1992 +A2:2009 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 The following BSI references relate to the work on this standard: Committee reference CIL/20 Draft for comment 91/31861 DC Committees responsible for this British Standard The preparation of this British Standard was entrusted by the Cables and Insulation Standards Policy 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 Plastics 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 Electrical 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 Equipment 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 © BSI 2008 ISBN 978 0 580 63230 3 Amendment 31 December 2008 See foreword No. 2 BS 7609:1992+A2:2009 i Contents Page Committees responsibleInside front cover Forewordii 1Scope1 2References1 3Definitions1 4Compression connectors1 5Mechanical connectors8 6Bolting of terminal 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 termination4 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 © BSI 2008 BS 7609:1992+A2:2009 ii Foreword This British Standard has been prepared under the direction of the Cables and Insulation Standards Policy Committee. BS 7609 is intended 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 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 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, 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. 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 2008 BS 7609:1992+A2:2009 The start and finish of text introduced or altered by Amendments No. 1 and No.2 is indicated in the text by tags and . 1 1 Scope This British Standard recommends methods and procedures applicable for the installation of uninsulated compression and mechanical connectors 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, 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, any of these publications apply to this standard only when incorporated 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. 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 by 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 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 equipment 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 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 conductor 4.2.1 General The insulation should be stripped back so that when assembled 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 conductors Unless 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 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 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 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. © BSI 2008 BS 7609:1992+A2:2009 2 © BSI 2008 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. 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. 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 for 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 twisting 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. With 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 and order of compression operations (if multiple) and whether overlapping is necessary or permissible. Care should be taken to ensure the correct connector 4.4 Inspection of completed compression connection The completed connector should be examined to ensure: a) the correct connector reference relative 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 has been fully inserted. NOTE 1Examples of typical die sets, bolted terminations and good and poor 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. of both copper and aluminium connectors the the connector and die-set should be as specified by the manufacturer. The installer should ensure that the compression tool used is fully compatible with the crimp dies and that the dies fully close during the crimp operation. c) a completed compression is free from excessive a) For hexagon and circumferential crimping b) that the correct die set has been used; b) For indent type crimping of both copper and aluminium connectors the connector, die-set and tooling should be as specified by the manufacturer. Specific attention should be paid to the servicing and calibration of the compression tool in order to guarantee the indent dies are compressed 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 connector satisfactory type test.manufacturers BS 7609:1992+A2:2009 3 Figure 1 Illustrations of compression die sets Figure 2 Illustrations of bi-metallic connector © BSI 2008 BS 7609:1992+A2:2009 4 Figure 3 Examples of correct and incorrect bolted termination © BSI 2008 BS 7609:1992 A2:2009+ 5 Figure 4 Examples of correct and incorrect compression preparation © BSI 2008 BS 7609:1992+A2:2009 6 © BSI 2008 Figure 5 Illustrations of three compression styles in use BS 7609:1992+A2:2009 7 Figure 6 Examples of common compression faults © BSI 2008 BS 7609:1992+A2:2009 8 © BSI 2008 5 Mechanical connectors 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 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 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. 5.2.2 Aluminium conductor Unless 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 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 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 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 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 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. Where the surface appears oxidized, abrade the conductor surface by following the same procedure as recommended for aluminium conductors (see 5.2.2). A separate brush should be kept for this material type. 5.3 Assembly of connector After cleaning the conductor, the connector should be assembled as follows: a) insert any interface material or apply jointing compounds if specified by the manufacturer; b) fit connector around the conductor and complete assembly according to manufacturers instructions; c) tighten clamp screws consecutively one turn at a time until either: 1) any torque-limiting device operates; or 2) until the manufacturers recommended tightening torque has been reached. 5.4 Inspection of completed mec