DRAFT MALAYSIAN STANDARD 14E003R0 j STAGE : PUBLIC COMMENT (40.20) DATE : 01/08/2015-30/09/2015 Crimping type hexagon dies for cable lugs, cable links and the rounding dies for sector cable - Installation method and specification for the materials, marking and dimensions OFFICER/SUPPORT STAFF: (ZZ / ) ICS: 29.060 Descriptors: crimping hexagon dies and rounding dies for cable lug and link, copper, low voltage applications, specification for material, marking, dimension Copyright DEPARTMENT OF STANDARDS MALAYSIA
Contents Page Committee representation...ii Foreword... iii Introduction...iv 1 Scope... 1 2 Normative reference... 1 3 Definitions... 2 4 Requirements... 2 5 Requirements for rounding die... 5 6 Type test... 6 STANDARDS MALAYSIA 2015 - All rights reserved i
Committee representation The Industry Standards Committee on Generation, Transmission and Distribution of Energy (ISC E) under whose authority this Malaysian Standard was developed comprises representatives from the following organisations: Association of Consulting Engineers Malaysia Department of Standards Malaysia Federation of Malaysian Manufacturers Jabatan Kerja Raya Malaysia Malaysia Nuclear Power Corporation Malaysian Association of Standards Users Malaysian Cable Manufacturers Association Malaysian Electrical Appliances and Distributors Association Malaysian Green Technology Corporation Persatuan Kontraktor Elektrikal dan Mekanikal Melayu Malaysia SIRIM Berhad (Secretariat) SIRIM QAS International Sdn Bhd Sabah Electricity Sdn Bhd Sarawak Energy Berhad Suruhanjaya Komunikasi dan Multimedia Malaysia Suruhanjaya Tenaga Sustainable Energy Development Authority Malaysia Tenaga Nasional Berhad The Electrical and Electronics Association of Malaysia The Institution of Engineers, Malaysia Universiti Malaya The Technical Committee on Electrical Installation, Protection and Insulation Practice which developed this Malaysian Standard was managed by The Electrical and Electronics Association of Malaysia in its capacity as an authorised Standards Writing Organisation and consists of representatives from the following organisations: Association of Consulting Engineers Malaysia EITA Resources Bhd G.H. Liew Engineering (1990) Sdn Bhd Jabatan Bomba dan Penyelamat Malaysia Jabatan Kerja Raya Malaysia Sabah Electricity Sdn Bhd Sarawak Energy Berhad SIRIM QAS International Sdn Bhd Suruhanjaya Tenaga The Electrical and Electronics Association of Malaysia (Secretariat) The Institution of Engineers, Malaysia Time Era Sdn Bhd Tenaga Nasional Berhad (Distribution Division) Tenaga Nasional Berhad (Generation Division) Universiti Malaya The Working Group on Cable Lugs, Tools and Dies which developed this Malaysia Standard consists of representatives from the following organisation : Abbaco Controls Sdn Bhd Conway Terminals Manufacturer Sdn Bhd Covis Sdn Bhd The Electrical and Electronics Association of Malaysia (Secretariat) The Institution of Engineers, Malaysia ii STANDARDS MALAYSIA 2015 - All rights reserved
Foreword This Malaysian Standard was developed by the Technical Committee on Electrical Installation, Protection and Insulation Practice under the authority of the Industry Standards Committee on Generation, Transmission and Distribution of Energy. Development of this standard was carried out by The Electrical and Electronics Association of Malaysia (TEEAM) which is the Standards Writing Organisation (SWO) appointed by SIRIM Berhad to develop standards for electrical installation, protection and insulation practice. Compliance with a Malaysian Standard does not of itself confer immunity from legal obligations. STANDARDS MALAYSIA 2015 - All rights reserved iii
Introduction This Malaysian Standard is meant to standardize and prevent the use of non-matching die for cable lugs, cable links and sector copper conductor in Low Voltage applications where the sector cable needs to be rounded for easy entry into the barrel of connector. This is necessary as non-standard die are currently widely used in Malaysia. This standard contains the guidelines for the overall installation method and dimension of hexagon dies to suite Malaysian Standard cable lugs and cable links and rounding dies for sector copper conductor in low voltage applications. iv STANDARDS MALAYSIA 2015 - All rights reserved
Crimping type hexagon dies for cable lugs, cable links and the rounding dies for sector cable - Installation method and specification for the materials, marking and dimensions 1 Scope The Malaysian Standard specifies the overall installation method, dimension and material of hexagon die to crimp cable lugs and cable links for and with copper conductor in low voltage applications, up to the maximum of 1kV. Dimensions provided are the across flat of the hexagon and width of the hexagon die. Also included are the material specifications, finishing and die marking. This Malaysia standard also covers the rounding dies for sector copper conductor in low voltage applications, where the sector cable needs to be rounded for easy entry into the barrel of connector. The rounding dies specification provided includes the diameter of the die and width, material, finishing and die marking. This standard applies to cable lugs and cable links for the conductor of power cables and the secondary wiring with cross section 16 mm 2 to 1000 mm 2 for Copper conductors. The coverage of this standard is limited to cable lugs and links for low voltage applications as per IEC 60228. This standard is applicable to all MS 1540 cable lugs and MS 1779 cable links. 2 Normative references The following normative references are indispensable for the application of this standard. For dated references, only the edition cited applies. For undated references, the latest edition of the normative reference (including any amendments) applies. MS 1540, Specification for material, marking and dimension of crimp type cable lugs for use with copper conductors in low voltage applications MS 1779, Crimp type cable links as through-connectors for and with stranded (non-compact) copper conductors in low voltage applications - Specification for the material, marking and dimension IEC 60228, Conductors of insulated cables IEC 61238-2, Compression and mechanical connectors for power cables with copper or aluminium conductors - Part 2: Terminal lugs for power cables to fit equipment up to and including 1 kv - Overall dimensions STANDARDS MALAYSIA 2015 - All rights reserved 1
3 Terms and definitions For the purposes of this standard, the following terms and definitions apply. 3.1 connector Device for connecting a conductor to an equipment terminal or for connecting two or more conductors to each other. 3.2 cable lug Connector comprising a palm and a connector barrel, for connecting a conductor to an equipment terminal. The cable lug mentioned in this Malaysian Standard, applies to crimp type cable lugs for low voltage applications. 3.3 cable link Through-connector comprising a barrel for the connecting of two same sizes copper conductors into a splice. The cable link mentioned in this standard, applies to crimp type cable links for low voltage applications. 3.4 connector barrel Full length solid drawn copper tube, with a central dent, into which two conductors can be inserted and positioned to form a through joint. 3.5 joint Assembly comprising the connector barrel and two ends of the conductors in the same run which have been brought into immediate contact with it during the crimping process. 3.6 crimp Method of securing a connector to a conductor by using a special tool to produce permanent deformation of the connector and the conductor. 4 Requirements 4.1 Requirements for hexagon die 4.1.1 Material specification The material specification is as follows: a) Tool steel, hardened to 40 RC; b) smooth surface and no sharp edge on die; and c) chrome all surface of die. 2 STANDARDS MALAYSIA 2015 - All rights reserved
4.1.2 Marking of hexagon die The marking of hexagon die is as follows: a) By engraving or laser printing outside of the die, copper conductor, the size and number of crimps; and b) by engraving the cable size on the crimping surface. The example of markings is shown in Figure 1, 2 and 3. Figure 1. Example of marking on a 16 mm 2 hexagon die Figure 2. Example of marking on a 240 mm 2 hexagon die STANDARDS MALAYSIA 2015 - All rights reserved 3
Figure 3. Example of marking on a 630 mm 2 hexagon die Key CU - Copper 16-16 mm 2 X1 - Crimp 1 time 240-240 mm 2 X2 - Crimp 2 times 630-630 mm 2 X3 - Crimp 3 times 4.2 Dimension of hexagon die The dimension of hexagon dies is shown in Figure 4. Figure 4. Dimension of hexagon die 4 STANDARDS MALAYSIA 2015 - All rights reserved
The dimension of hexagon dies shall comply with the values in Table 1. NOTES: Cable size (mm 2 ) Table 1. Dimension of hexagon die Hexagon across flat (mm) ±0.2 Minimum crimping width (mm) ±0.2 16 mm 2 6.4 7.5 25 mm 2 7.7 9.0 35 mm 2 8.9 10.0 50 mm 2 10.3 12.0 70 mm 2 11.9 12.5 95 mm 2 14.5 14 120 mm 2 15.7 18 150 mm 2 17.6 19 185 mm 2 19.5 20 240 mm 2 22.6 24 300 mm 2 25.2 27 400 mm 2 28.0 28 500 mm 2 31.0 36 630 mm 2 35.3 36 800 mm 2 40.1 45 1000 mm 2 44.1 60 1. Single crimp or multiple crimps are acceptable 2. For barrel outer diameter of Cable Lugs refer to MS 1540 and Cable Links refer to MS 1779 5 Requirements for rounding die 5.1 Material specification The material specification is as follows: a) Tool steel, hardened to 40 RC; b) chrome all surface of die; and c) smooth surface and not sharp edge 5.2 Marking and dimension of rounding die By engraving or laser printing on the surface of the die. STANDARDS MALAYSIA 2015 - All rights reserved 5
Figure 5. Marking and dimension of 185 mm 2 rounding die Key CU - Copper 185-185 mm 2 6 STANDARDS MALAYSIA 2015 - All rights reserved
The dimension of Rounding Dies shall comply with the values in Table 2. NOTES: Sector cable size (mm 2 ) Table 2. Dimension of rounding die Width of pre-rounding dies (±0.3 mm) Diameter of pre-rounding dies (±0.2 mm) 35 mm 2 16 8.0 50 mm 2 19 9.0 70 mm 2 20 10.5 95 mm 2 22 12.5 120 mm 2 29 13.6 150 mm 2 31 15.8 185 mm 2 33 17.5 240 mm 2 44 20 300 mm 2 46 22 400 mm 2 47 24.5 1. Single crimp or multiple crimps are acceptable 2. For barrel internal diameter, refer to MS 1540 for Cable Lugs, MS 1779 for Cable Links 3. For outer diameter of the conductor, refer to IEC 60228 standard on conductors of insulated cables 6 Type test Unless specified otherwise, the crimped lugs and links using the above dimension dies shall pass the type test in accordance with IEC 61238-1 for class B. 6.1 Heat cycle test The total number heat cycles is dependent on purchaser s requirement and is divided into two categories: a) Category I : Base on purchaser introduction, the total number of heat cycle for this type test shall be three hundred (300), the electrical resistance measurements and temperature measurements shall be taken at the start of test and thereafter at every fifty (50) cycle interval (in total 7 measurement); and b) Category II : 1000 heat cycle, test procedures are according IEC 61238-1. STANDARDS MALAYSIA 2015 - All rights reserved 7
Acknowledgements Members of Technical Committee on Electrical Installation, Protection and Insulation Practice Ir Rocky Wong Hon Thang (Chairman) The Electrical and Electronics Association of Malaysia Ms Khong Choy Tai (Secretary) Ir Ahmad Rashidi Zainudin Mr Lim Siang Leong Ir Chew Shee Fuee Ir Lim Kim Ten Dato Rusmani Muhamad Dato Ir Haji Mohd Fazli Osman/ Ir Nizar Othman Mr Khung Chiang Sing/ Mr Chong Kok Leong Mr Hii Hii Kwong Mr Surian Rasol Haji Abdul Aziz Abdul Rahman Mr Nageswara Rao Ir Tan Chow Heang Mr Nur Azlan Abdul Malek Prof Dr Hew Wooi Ping/ Dr Che Hang Seng The Electrical and Electronics Association of Malaysia Association of Consulting Engineers Malaysia EITA Resources Bhd G. H. Liew Engineering (1990) Sdn Bhd The Institution of Engineers Malaysia Jabatan Bomba dan Penyelamat Malaysia Jabatan Kerja Raya Malaysia Sabah Electricity Sdn Bhd Sarawak Energy Berhad SIRIM QAS International Sdn Bhd Suruhanjaya Tenaga Time Era Sdn Bhd Tenaga Nasional Berhad (Distribution Division) Tenaga Nasional Berhad (Generation Division) Universiti Malaya Members of Working Group on Cable Lugs, Tools and Dies Ir Rocky Wong Hon Thang Ir Chang Yew Cheong Mr Ng Choon Guan/ Mr Albert Tan Mr Lawrence Lai Kun Hoong Ir Lim Kim Ten The Electrical and Electronics Association of Malaysia Abbaco Controls Sdn Bhd Conway Terminals Manufacturer Sdn Bhd Covis Sdn Bhd The Institution of Engineers, Malaysia STANDARDS MALAYSIA 2015 - All rights reserved