1、 Collection of SANS standards in electronic format (PDF) 1. Copyright This standard is available to staff members of companies that have subscribed to the complete collection of SANS standards in accordance with a formal copyright agreement. This document may reside on a CENTRAL FILE SERVER or INTRA
2、NET SYSTEM only. Unless specific permission has been granted, this document MAY NOT be sent or given to staff members from other companies or organizations. Doing so would constitute a VIOLATION of SABS copyright rules. 2. Indemnity The South African Bureau of Standards accepts no liability for any
3、damage whatsoever than may result from the use of this material or the information contain therein, irrespective of the cause and quantum thereof. ISBN 978-0-626-22155-3 SANS 1803-1:2009Edition 1.1 Any reference to SABS 1803-1 is deemed to be a reference to this standard (Government Notice No. 1373
4、of 8 November 2002) SOUTH AFRICAN NATIONAL STANDARD Lugs and ferrules for insulated electric cables Part 1: Copper conductors Published by SABS Standards Division 1 Dr Lategan Road Groenkloof Private Bag X191 Pretoria 0001Tel: +27 12 428 7911 Fax: +27 12 344 1568 www.sabs.co.za SABS SANS 1803-1:2009
5、 Edition 1.1 Table of changes Change No. Date Scope Amdt 1 2009 Amended to change the designation of SABS standards to SANS standards, to update referenced standards, and to remove a reference to the SABS as the testing authority. Foreword This South African standard was approved by National Committ
6、ee SABS TC 66, Electric cables, in accordance with procedures of the SABS Standards Division, in compliance with annex 3 of the WTO/TBT agreement. This document was published in May 2009. This document supersedes SABS 1803-1:2002 (edition 1). A vertical line in the margin shows where the text has be
7、en technically modified by amendment No. 1. SANS 1803-1:2009 Edition 1.1 1 Contents Page Foreword 1 Scope . 3 2 Normative references . 3 3 Definitions 3 4 General requirements 4 5 Dimensions 5 5.1 Lugs 5 5.2 Ferrules 8 5.3 Crimping dies . 10 6 Tests . 11 6.1 Sample tests . 11 6.2 Type approval test
8、. 12 SANS 1803-1:2009 Edition 1.1 2 This page is intentionally left blankSANS 1803-1:2009 Edition 1.1 3 Lugs and ferrules for insulated electric cables Part 1: Copper conductors 1 Scope 1.1 This standard specifies the leading dimensions and test requirements for lugs and ferrules for use in terminat
9、ing and joining conductors of insulated electric cables, having compacted stranded, or uncompacted stranded conductors in the size range 10 mm to 630 mm. 1.2 This standard covers lugs and ferrules for attaching to the conductor by compression, using special tools. Soldered lugs are not included. 1.3
10、 This standard does not apply to compression joints on overhead conductors, which are designed to withstand high tensile forces, or to pre-insulated lugs. 2 Normative references The following standards contain provisions which, through reference in this text, constitute provisions of this standard.
11、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. I
12、nformation on currently valid national and international standards can be obtained from the SABS Standards Division. EN 10083-1, Steels for quenching and tempering Part 1: General technical delivery conditions. SANS 1411-1, Materials of insulated electric cables and flexible cords Part 1: Conductors
13、. SANS 61238-1/IEC 61238-1, Compression and mechanical connectors for power cables for rated voltages up to 30 kV (Um = 36 kV) Part 1: Test methods and requirements. 3 Definitions For the purposes of this standard, the following definitions and those given in SANS 1411-1 and SANS 61238-1 apply. In t
14、he case of conflicting requirements, the definitions given below take precedence. Amdt 1 SANS 1803-1:2009 Edition 1.1 4 3.1 acceptable acceptable to the authority administering this standard or to the parties concluding the purchase contract, as relevant 3.2 compacted stranded conductor stranded con
15、ductor that has had its overall dimensions reduced by mechanical means 3.3 uncompacted stranded conductor conductor that has been stranded in layers with no subsequent mechanical compaction 3.4 sample test test conducted on a regular basis at the manufacturers works or on representative samples take
16、n by the manufacturer, or as requested by the purchaser at the time of enquiry or order 3.5 type approval test test conducted before a lug or ferrule covered by this standard is supplied on a general commercial basis, in order to demonstrate that it has the necessary performance characteristics for
17、the intended application. The test is of such a nature that, after it has been successfully completed, it need not be repeated unless changes are made to the materials or design that might affect its performance 4 General requirements 4.1 Sizing Lugs and ferrules made to this standard shall be desig
18、ned to fit a specific conductor size and shall be marked with a number to indicate the conductor size in square millimetres. Where, on the larger sizes, significant differences exist in the diameters of compacted and uncompacted conductors, two sizes of connector shall be included, the code letters
19、XL identifying the lug or ferrule intended for use on compacted conductors. 4.2 Material Lugs and ferrules made to this part of the standard shall be of electrolytic grade copper, and may be bare or tinned. 4.3 Finish The surface finish as visually examined according to 6.1, shall be clean and be fr
20、ee of all defects such as burrs, cracks, rolled seams, blisters, twists, press and chatter marks. The faces of the palms of the lugs shall be flat and smooth. Fixing holes shall be free of burrs. The entry to the barrel of the lug or ferrule shall be profiled to facilitate entry of the conductor eit
21、her by radiusing, chamfering or belling the entry point. 4.4 Marking Where practical, the non-contacting side of the palm of a lug shall be stamped or otherwise indelibly marked with the manufacturers name or trademark and the conductor size. Ferrules shall be similarly marked in the centre or at on
22、e end. If so required for the crimping procedure, the barrels of lugs and ferrules shall be marked to indicate the correct crimping positions, and if necessary also, the correct sequence of crimping (see 6.1).SANS 1803-1:2009 Edition 1.1 5 5 Dimensions 5.1 Lugs 5.1.1 Special requirements Lugs to be
23、used on low voltage cables shall be supplied with an inspection hole. Lugs to be used on medium voltage cables and all lugs designated XL in table 1 shall be supplied without an inspection hole. 5.1.2 Leading dimensions The following dimensions for single hole fixing lugs are given in table 1. All d
24、imensions are in millimetres. Figure 1 Leading dimensions of lugs with single hole fixing D2 External diameter of barrel D1 Internal diameter of barrel A Insertion depth B Length of palm C Distance of fixing hole centre line from end of lug W Width of palm S Fixing hole to suit stud or bolt of diame
25、ter S SANS 1803-1:2009 Edition 1.1 6 Table 1 Dimensions of single-hole-fixing lugs for compacted (XL) and uncompacted copper conductors 1 2 3 4 5 6 7 8 9 Barrel dimensions Palm dimensions D1 D2 A S B W C Conductor size mm mm mm mm Fixing hole to suit stud size, M mm mm mm mm mm 10 4,4 6,3 12 6* 8 16
26、 5,5 7,6 12 8* 10 12 25 6,9 9,0 15 8* 10 12 Palm dimensions of lugs in the size range 10 mm2to 95 mm2are governed by size of stud 35XL 7,3 10,5 16 8* 10 12 35 8,2 10,7 15 8* 10 12 M6 18 13 9 50XL 8,8 12,3 20 8* 10 12 50 10,0 12,8 16 8* 10 12 M8 20 17 10 70XL 10,4 14,6 21 10* 12 M10 24 21 12 70 11,7
27、15,0 21 10* 12 95XL 12,1 17,0 24 10* 12 M12 27 24 13 95 13,5 17,4 23 10* 12 120XL 14,0 19,1 26 12* M12 28 25 13 120 15,5 19,8 26 12* M12 28 25 13 150XL 15,3 21,3 31 12* M12 32 30 15 150 17,0 22,0 27 12* M12 32 30 15 185XL 17,0 23,7 34 12* M12 34 32 16 185 19,0 24,4 29 12* M12 34 32 16 240XL 20,0 27,
28、1 34 12* M12 38 36 16 240 21,5 27,7 33 12* M12 38 36 16 300XL 21,6 30,5 38 12* M12 40 38 16 300 24,5 31,3 35 12* M12 40 38 16 400XL 24,5 34,6 51 16* M16 45 42 21 400 27,5 35,6 41 16* M16 45 42 21 500XL 28,5 38,9 51 16* M16 52 50 25 500 31,6 40,0 41 16* M16 52 50 25 630XL 33,0 45,0 53 16* M16 65 60 2
29、8 630 34,5 44,6 53 16* M16 65 60 28 NOTE 1 Tolerances permitted on the tabulated dimensions are as follows: Internal diameter of lug barrel (D1) External diameter of lug barrel (D2) Insertion depth (A) Length of palm (B) Width of palm (W) Fixing hole centre line to end of lug (C) : -0 +0,1 mm : -0 +
30、 0,1 mm : -0 +1,0 mm : -0 + 2,0 mm : -0 +1,0 mm : Where dimension (B) is greater than the minimum specified, the maximum value of dimension (C) may be any value up to half the actual value of dimension (B). NOTE 2 Clearance holes marked * are the preferred sizes. Alternative hole sizes are given for
31、 lugs in the size range 10 mm2to 95 mm2. If other fixing hole sizes are required, the purchaser should consult the manufacturer. NOTE 3 Where a lug is to be fitted to a shaped conductor, the conductor should be circularized and the lug designed for the same size of uncompacted circular conductor fit
32、ted. Amdt 1 SANS 1803-1:2009 Edition 1.1 7 5.1.3 Dimensions for special lugs The following dimensions for special lugs for terminating cables into moulded circuit breakers are given in table 2. Table 2 Special lugs for terminating cables into moulded case circuit breakers 1 2 3 4 5 6 7 8 Barrel dime
33、nsions Palm dimensions D1 D2 A S B W C Conductor size mm mm mm mm mm mm mm mm 10 4,4 6,3 11 M8 17 13 7,5 16 5,5 7,6 12 M8 18 13 7,5 25 6,9 9,0 15 M8 17 14 8 35 8,2 10,7 15 M8 18 16 9 50 10,0 12,8 16 M8 17 16 9 70 11,7 15,0 20,5 M8 20 20 9,5 95 13,5 17,4 23 M8 24 20 9,5 120 15,5 19,8 26 M8 28 20 9,5
34、150 17,0 22,0 27 M12 33 32 16 185 19,0 24,4 29 M12 31 34 16 240 21,5 27,7 33 M12 36 40 16 300 24,5 31,3 35 M12 35 40 16 400 27,5 35,6 41 M12 45 40 16 400 27,5 35,6 41 2 x M12 76 40 500 31,6 40,0 41,5 2 x M12 76 40 630 34,5 44,6 53 2 x M12 76 40 See detail in figure 2 NOTE 1 Tolerances permitted on t
35、he tabulated dimensions are as follows: Internal diameter of lug barrel (D1) : -0 +0,1 mm External diameter of lug barrel (D2) : -0 + 0,1 mm Insertion depth (A) : -0 +1,0 mm Length of palm (B) : minimum Width of palm (W) : -1,0 + 0 mm Fixing hole centre line to end of lug (C) : Where dimension (B) i
36、s greater than the minimum specified, the maximum value of dimension (C) may be any value up to half the actual value of dimension (B). SANS 1803-1:2009 Edition 1.1 8 Dimensions in millimetres Figure 2 Palm dimensions of special two-hole fixing lugs 5.2 Ferrules 5.2.1 Special requirements Ferrules f
37、or use on paper cable joints or on paper/cross-linked polyethylene (XLPE) transition joints shall be provided with a solid centre. To ensure correct fitment, all ferrules shall be provided with a dimple or a circumferentially rolled indent at the centre point. 5.2.2 Leading dimensions The following
38、dimensions for ferrules are given in table 3. All dimensions are in millimetres. Figure 3 Leading dimensions of ferrules D1 = Internal diameter of barrel D2 = External diameter of barrel L = Overall length SANS 1803-1:2009 Edition 1.1 9 Table 3 Leading dimensions of ferrules for compacted (XL) and u
39、ncompacted copper conductors 1 2 3 4 Dimensions D1 D2 L Conductor size mm mm mm mm 10 4,4 6,3 22 16 5,5 7,6 22 25 6,9 9,0 24 35XL 7,3 10,5 38 35 8,2 10,7 27 50XL 8,8 12,3 42 50 10,0 12,8 30 70XL 10,4 14,6 43 70 11,7 15,0 34 95XL 12,1 17,0 45 95 13,5 17,4 38 120XL 14,0 19,1 55 120 15,5 19,8 42 150XL
40、15,3 21,3 58 150 17,0 22,0 48 185XL 17,0 23,7 64 185 19,0 24,4 53 240XL 20,0 27,1 70 240 21,5 27,7 60 300XL 21,6 30,5 75 300 24,5 31,3 67 400XL 24,5 34,6 80 400 27,5 35,6 80 500XL 28,5 38,9 90 500 31,0 40,0 90 630XL 33,0 45,0 100 630 34,5 44,6 110 NOTE Tolerances permitted on the tabulated dimension
41、s are as follows: Internal diameter of ferrule : -0 +0,1 mm Outside diameter of ferrule : -0 +0,1 mm Length of ferrule : -0 +1,0 mm SANS 1803-1:2009 Edition 1.1 10 5.3 Crimping dies 5.3.1 Requirement Lugs and ferrules to SANS 1803-1 shall be fitted to the conductor using crimping dies in accordance
42、with the requirements of 5.3.2 to 5.3.5. 5.3.2 Dimensions Crimping dies shall be made to the dimensions given in table 4. Dimension (A), the across the flats dimension, and (W), the web width of the crimping die, shall be as given in table 4, other dimensions to suit the compression tooling. Two web
43、 widths, W1 and W2, are specified in the table. W1 is for hydraulic tooling W2 is for hand-operated tooling 5.3.3 Material Crimping dies shall be made from steel, grade 36 NiCrMo16, in accordance with EN 10083-1. 5.3.4 Finish All sharp edges and burrs shall be removed and faces of the die which come
44、 in contact with one another, or with the lug or ferrule to be crimped, shall be polished to a mirror finish. 5.3.5 Identification Both halves of the crimping die shall be identical and shall be stamped or engraved with numerals to identify the size of the die. Both halves of the crimping die shall
45、be stamped or engraved with mirrored numerals as shown in figure 4. The stamping or engraving shall be deep enough to ensure that the size of the crimping die used is clearly visible on the lug or ferrule after it has been crimped on to the conductor. Figure 4 Leading dimensions of crimping die A =
46、Across the flats dimension W = Web width of the crimping die SANS 1803-1:2009 Edition 1.1 11 Table 4 Leading dimensions of crimping dies 1 2 3 4 5 6 7 Tool dimensions Single or double crimp A W1 W2 Conductor size mm2mm mm mm W1 Hydraulic W2 Hand Identification 10 5,10 10,50 5,0 Single Double 10 SANS
47、 1803-1 16 6,10 10,50 5,0 Single Double 16 SANS 1803-1 25 7,15 13,00 5,0 Single Double 25 SANS 1803-1 35 8,50 13,00 5,0 Single Double 35 SANS 1803-1 50 10,00 13,00 5,0 Single Double 50 SANS 1803-1 70 11,89 13,00 5,0 Single Double 70 SANS 1803-1 95 13,85 13,00 5,0 Single Double 95 SANS 1803-1 120 15,
48、60 13,00 5,0 Single Double 120 SANS 1803-1 150 17,52 10,50 Double 150 SANS 1803-1 185 19,54 10,50 Double 185 SANS 1803-1 240 22,00 10,50 Double 240 SANS 1803-1 300 24,38 10,50 Double 300 SANS 1803-1 400 28,40 10,50 Double 400 SANS 1803-1 500 32,40 17,00 Double 500 SANS 1803-1 630 37,80 17,00 Double
49、630 SANS 1803-1 NOTE Tolerances permitted on the tabulated dimensions are as follows: Across flats (A) 10 mm2to 50 mm2+ 0 - 0,05 mm above 50 mm2 + 0 - 0,10 mm Web width (W) all sizes + 0,1 - 0,1 mm 6 Tests 6.1 Sample tests Select 10 specimens at random from each 1 000 units of the same size manufactured. Examine each specimen visually for compliance with 4.3 and 4.4, and check for dimensional compliance with this specification. If two specimens of the samp
