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ANSI C119.1-2006

American National Standard


for Electric Connectors
Sealed Insulated Underground
Connector Systems
Rated 600 Volts

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ANSI C119.1-2006

American National Standard


For Electric Connectors
Sealed Insulated Underground Connector Systems
Rated 600 Volts

Secretariat:

National Electrical Manufacturers Association


Approved January 13, 2006

American National Standards Institute, Inc.

ANSI C119.1-2006

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NOTICE AND DISCLAIMER


The information in this publication was considered technically sound by the consensus of
persons engaged in the development and approval of the document at the time it was
developed. Consensus does not necessarily mean that there is unanimous agreement
among every person participating in the development of this document.
NEMA standards and guideline publications, of which the document contained herein is one,
are developed through a voluntary consensus standards development process. This process
brings together volunteers and/or seeks out the views of persons who have an interest in the
topic covered by this publication. While NEMA administers the process and establishes rules to
promote fairness in the development of consensus, it does not write the document and it does
not independently test, evaluate, or verify the accuracy or completeness of any information or
the soundness of any judgments contained in its standards and guideline publications.
NEMA disclaims liability for any personal injury, property, or other damages of any nature
whatsoever, whether special, indirect, consequential, or compensatory, directly or indirectly
resulting from the publication, use of, application, or reliance on this document. NEMA
disclaims and makes no guaranty or warranty, express or implied, as to the accuracy or
completeness of any information published herein, and disclaims and makes no warranty that
the information in this document will fulfill any of your particular purposes or needs. NEMA does
not undertake to guarantee the performance of any individual manufacturer or sellers products
or services by virtue of this standard or guide.
In publishing and making this document available, NEMA is not undertaking to render
professional or other services for or on behalf of any person or entity, nor is NEMA
undertaking to perform any duty owed by any person or entity to someone else. Anyone using
this document should rely on his or her own independent judgment or, as appropriate, seek
the advice of a competent professional in determining the exercise of reasonable care in any
given circumstances. Information and other standards on the topic covered by this publication
may be available from other sources, which the user may wish to consult for additional views
or information not covered by this publication.
NEMA has no power, nor does it undertake to police or enforce compliance with the contents
of this document. NEMA does not certify, test, or inspect products, designs, or installations for
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or safetyrelated information in this document shall not be attributable to NEMA and is solely
the responsibility of the certifier or maker of the statement.

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AMERICAN
NATIONAL
STANDARD

ANSI C119.1-2006

Approval of an American National Standard requires verification by


ANSI that the requirements for due process, consensus, and other
criteria for approval have been met by the standards developer.
Consensus is established when, in the judgment of the ANSI Board of
Standards Review, substantial agreement has been reached by directly
and materially affected interests. Substantial agreement means much
more than a simple majority, but not necessarily unanimity. Consensus
requires that all views and objections be considered, and that a
concerted effort be made toward their resolution.
The use of American National Standards is completely voluntary; their
existence does not in any respect preclude anyone, whether he has
approved the standards or not, from manufacturing, marketing,
purchasing, or using products, processes, or procedures not
conforming to the standards.
The American National Standards Institute does not develop standards
and will in no circumstances give an interpretation of any American
National Standard. Moreover, no person shall have the right or
authority to issue an interpretation of an American National Standard in
the name of the American National Standards Institute. Requests for
interpretations should be addressed to the secretariat or sponsor
whose name appears on the title page of this standard.
Caution Notice: This American National Standard may be revised or
withdrawn at any time. The procedures of the American National
Standards Institute require that action be taken periodically to reaffirm,
revise, or withdraw this standard. Purchasers of American National
Standards may receive current information on all standards by calling or
writing the American National Standards Institute.

Published by:

National Electrical Manufacturers Association


1300 North 17th Street, Rosslyn, VA 22209
Copyright 2006 by National Electrical Manufacturers Association
All rights reserved including translation into other languages, reserved under the Universal Copyright
Convention, the Berne Convention for the Protection of Literary and Artistic Works, and the
International and Pan American Copyright Conventions.
No part of this publication may be reproduced in any form, in an electronic retrieval system or otherwise, without the prior written
permission of the publisher.

Printed in the United States of America.

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ANSI C119.1-2006

Contents
Page

Foreword
1

........................................................................................................................ vii

Scope and Purpose .......................................................................................................1


1.1

Scope .............................................................................................................1

1.2

Purpose.............................................................................................................1

Referenced American National Standard ......................................................................1

Definitions

Test Conditions ..............................................................................................................2

.............................................................................................................1

4.1

General .............................................................................................................2

4.2

Current cycle .....................................................................................................2

4.3

Mechanical tests ...............................................................................................2

4.4

Thermal stability test .........................................................................................2

4.5

Integrity of seal and connector insulation test...................................................2

Performance...................................................................................................................2
5.1

General .............................................................................................................2

5.2

Resistance ........................................................................................................3

5.3

5.4

5.5

5.6

5.2.1

CCT resistance ....................................................................................3

5.2.2

CCST resistance..................................................................................3

Temperature......................................................................................................3
5.3.1

CCT temperature .................................................................................3

5.3.2

CCST temperature...............................................................................3

5.3.3

Stability determination for CCT and CCST3

Mechanical tests ...............................................................................................3


5.4.1

Tensile strength ...................................................................................3

5.4.2

Rated conductor strength ....................................................................3

5.4.3

Tension ................................................................................................3

Thermal performance of insulated system under load (ISUL)..........................4


5.5.1

Performance requirements for ISUL ....................................................4

5.5.2

Stability determination for ISUL ...........................................................4

5.5.3

Insulation..............................................................................................5

Integrity of seal and connector insulation .........................................................5


5.6.1

Insulation resistance ............................................................................5

5.6.2

Dielectric withstand ..............................................................................5

5.6.3

Leakage current ...................................................................................5

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Test Procedures, General..............................................................................................5


6.1

6.2

6.1.1

Description ...........................................................................................5

6.1.2

Family sample set ................................................................................5

Test assembly methods ....................................................................................5


6.2.1

Installation details ................................................................................5

6.2.2

Conductor preparation for electrical tests............................................5

6.2.3

Conductor preparation for mechanical tests........................................6

6.2.4

Connector preparation .........................................................................6

6.2.5

Connector installation ..........................................................................6

Current Cycling in Air .....................................................................................................6


7.1

7.2

Test assembly ...................................................................................................6


7.1.1

Conductors...........................................................................................6

7.1.2

Connectors...........................................................................................6

7.1.3

Equalizers ............................................................................................6

7.1.4

Conductor lengths................................................................................6

7.1.5

Control conductor.................................................................................7

7.1.6

Equivalent aluminum/copper conductors.............................................7

7.1.7

Multiple control conductors ..................................................................7

Loop configuration and location........................................................................8


7.2.1

CCT method.........................................................................................8

7.2.2

CCST method ......................................................................................8

7.3

Ambient conditions..........................................................................................10

7.4

Test current .....................................................................................................10

7.5

Temperature conditions ..................................................................................10

7.6

7.7

iv

Test connectors ................................................................................................5

7.5.1

CCT temperature conditions..............................................................10

7.5.2

CCST temperature conditions ...........................................................10

Current cycle periods ......................................................................................10


7.6.1

Current cycle-ON period ....................................................................10

7.6.2

CCT current cycle-OFF period...........................................................11

7.6.3

CCST current cycle-OFF period ........................................................11

Measurements ................................................................................................11
7.7.1

Resistance measurements ................................................................12

7.7.2

Temperature measurements .............................................................12

7.8

Maximum number of current cycles................................................................12

7.9

Evaluation interval...........................................................................................12

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7.9.1

Evaluation by the CCT method ..........................................................12

7.9.2

Evaluation by the CCST method .......................................................13

Tensile Strength ...........................................................................................................13


8.1

Test connectors ..............................................................................................13


8.1.1

8.2
9

ANSI C119.1-2006

Number of samples............................................................................13

Pullout test ......................................................................................................13

Thermal Stability of insulated system under load (ISUL).............................................13


9.1

Test assembly .................................................................................................13

9.2

Test conditions ................................................................................................13

9.3

Test current .....................................................................................................14

9.4

Measurements ................................................................................................14

10 Integrity of Seal and Connector Insulation...................................................................14


10.1

Assemblies for test..........................................................................................14

10.2

Procedural sequence ......................................................................................14

10.3

Water immersion for twenty-four (24) hours ...................................................14

10.4

Insulation resistance measurement ................................................................15

10.5

Dielectric withstand test ..................................................................................15

10.6

Heat conditioning ............................................................................................15

10.7

Flex .................................................................................................................15

10.8

Twist ................................................................................................................15

10.9

Cold conditioning ............................................................................................15

10.10

Current cycle and water submersion ..............................................................15

10.11

Leakage current test .......................................................................................16

11 Test Report ..................................................................................................................16


12 Marking ........................................................................................................................16
12.1

Connector system marking .............................................................................16

12.2

Assembly instructions .....................................................................................16

Figures
1

An example of a vertical test configuration 8

Flexing and Twisting ....................................................................................................17

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Tables
1

Test duration ..................................................................................................................2

Tensile load, AWG cable ...............................................................................................4

Tensile load, metric cable ..............................................................................................4

Conductor lengths for current cycle test, AWG sizes ....................................................7

Conductor lengths for current cycle tests, metric sizes .................................................7

Suggested initial test current to raise AWG control conductor temperature 100C ......9

Suggested initial test current to raise metric control conductor temperature 100C .....9

Minimum current cycle periods for AWG control conductors ......................................10

Minimum current cycle periods for metric control conductors .....................................11

10 Resistance and temperature measurement intervals ..................................................11

Annexes (Informative)

vi

Optional Tests to Meet the Requirements of UL 486D................................................18

Standards which are Applicable to C119.1 by Inference,


but Not Directly Referenced in the Standard ...............................................................19

Test Loop Diagrams.....................................................................................................20

Suggested Thermocouple Locations ...........................................................................22

Guarded Circuit ............................................................................................................24

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Foreword

ANSI C119.1-2006

(Neither this foreword nor any of the informative annexes is a part of American National Standard

C119.1-2006.)

The standard covers electrical, mechanical, and sealing requirements of connectors rated 600 volts and
installed underground.
This standard was initially developed by an EEI-NEMA Joint Committee on Underground Distribution
Connectors and Connector Systems and published by the American National Standards Institute in 1974.
Suggestions for improvement of this standard will be welcome. They should be sent to:
National Electrical Manufacturers Association
1300 North 17th Street, Suite 1752
Rosslyn, VA 22209
This standard was processed and approved for submittal to ANSI by the Accredited Standards Committee
on Connectors for Electrical Utility Applications, C119. Committee approval of this standard does not
necessarily imply that all committee members voted for its approval. At the time it approved this standard,
the ANSI ASC C119 Committee had the following members:
Douglas Harms, Chairman
Ronald Lai, Vice Chairman
Vince Baclawski, Secretary
Organization Represented:

Name of Representative:

Aluminum Association

Jean-Marie Asselin

Electric Utility Industry

Warren Hadley
Douglas Harms
James Harris
Harry Hayes
Curt Schultz
James Sprecher
Gerald Wasielewski
David West

National Electric Energy Testing, Research & Application Center

Thomas Champion

National Electric Manufacturers Association

David Dembowski
Pierre Guyot
Barry Johnson
Ronald Lai
Frank Muench
Greg Nienaber
Frank Stepniak
Carl Tamm
Carl Taylor
David Thompson
Allen Wilcox
James Zahnen

Rural Utilities Service (RUS)

Trung Hiu

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Tennessee Valley Authority

Jeffrey Nelson

Underwriters Laboratories, Inc.

Jake Killinger

Other

Peter Bowers
Stanley Hodgin

The C119.1 Subcommittee on Sealed Underground Connector Systems, which developed the revisions of
this standard, had the following members:
James Zahnen, Chairman
David West, Vice Chairman
Vince Baclawski, Secretary
Mike Ferretti
Pierre Guyot
Warren C. Hadley
Douglas P. Harms
Trung Hiu
Barry Johnson
Jake Killinger
Ronald Lai
Thomas McKoon
Richard Morin
Greg T. Nienaber
Walter Romanko
Curt Schultz
James D. Sprecher
Carl R. Tamm
Carl Taylor
Richard (Jeff) J. Waidelich
Gerald Wasielewski
David West
Allen Wilcox
James Zahnen

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AMERICAN NATIONAL STANDARD

ANSI C119.1-2006

For Electric Connectors


Sealed Insulated Underground Connector Systems Rated 600 Volts
1

Scope and Purpose

1.1

Scope

This standard covers sealed, insulated underground connector systems rated at six hundred (600) volts
for utility applications and establishes electrical, mechanical, and sealing requirements for sealed
underground connector systems.
1.2

Purpose

The purpose of this standard is to give reasonable assurance to the user that sealed, insulated
underground connector systems meeting the requirements of this standard will perform in a satisfactory
manner, provided they have been properly selected for the intended application and are installed in
accordance with the manufacturers recommendations.

Referenced American National Standard

This standard is intended to be used in conjunction with the following standards. When this referenced
standard is superseded by a revision approved by the American National Standards Institute, the
referenced revision shall apply. Standards that are referenced by inference are shown in Annex B
ASTM E4-89

Practices for Load Verification of Testing Machines

IEEE 837-2002

Qualifying Permanent Connections used in Substation Grounding

Definitions

CCST: Current Cycle Submersion Test where current cycle heating is done in air and cooling is done
using water submersion.
CCT: Current Cycle Test where current cycle heating and cooling are done in air.
connector: A device that joins two or more conductors for the purpose of providing a continuous
electrical path.
connector assembly: The connector system installed on the conductor(s).
connector system: A connector and its associated insulating and sealing components.
control cable: A conductor of the same type and size as the conductor in the current cycle loop that
would be at the highest temperature.
guarded circuit: A circuit used to eliminate or to minimize the current flow between the insulation and
conductor ends, caused by surface leakage currents.
input conductor: Supply side of the connector assembly.

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ISUL: Insulation System Under Load conditions.


output conductor: Load side of the connector assembly.
seal: An interface preventing the ingress of moisture and foreign matter into the connector assembly.
underground: Below grade application, including direct burial.

Test Conditions

Connectors shall be installed and tested for current carrying, mechanical, and sealing performance in
accordance with the conditions noted in 6.0 through 10.0.
4.1

General

The connector system shall meet the performance requirements specified in 5.0.
4.2

Current cycle

The connector shall be tested in accordance with 7.0 on bare conductors for the number of test cycles in
Table 1, depending on the choice of test method.

Table 1 Test Duration


Connector Class
Heavy Duty (Class A)

Number of Test Cycles for:


CCT Method
CCST Method
500
100

NOTEThe connector classification defines the severity of the heat aging test.

Exception: Copper-bodied connectors, for use with copper cable only, do not require current cycling in air.
This exception is provided since copper-bodied connectors, in conjunction with copper cable, do not
exhibit high thermal expansion and creep characteristics.
NOTEThis test is run on bare conductor to provide repeatability of test results.

4.3

Mechanical tests

Tests of the tensile strength of the connector shall be conducted in accordance with 8.0.
4.4

Thermal stability test

The thermal performance of the connector system shall be tested in accordance with 9.0.
4.5

Integrity of seal and connector insulation test

The integrity of the connector system seal and insulation shall be tested in accordance with 10.0.

Performance

5.1

General

Connectors shall conform to the appropriate performance requirements in 5.0 when installed and tested
in accordance with the methods specified in 7.0 through 10.0.

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5.2

ANSI C119.1-2006

Resistance

The resistance of the connection tested in accordance with 7.0 shall be stable. Stability is achieved if any
resistance measurement, including allowance for measurement error, does not vary by more than plus or
minus five percent (+/-5%) from the average of all the measurements at specified intervals during the
course of the test.
5.2.1

CCT resistance

The resistance of the connection tested by the Current Cycle Test method in accordance with 7.0 shall be
stable between the twenty-fifth (25th) cycle and the completion of the number of current cycles required in
4.2.
5.2.2

CCST resistance

The resistance of the connection tested by the Current Cycle Submersion Test method in accordance
with 7.0, shall be stable between the tenth (10th) cycle and the completion of the number of current
cycles required in 4.2.
5.3

Temperature

The temperature of the connector tested in accordance with 7.0 shall not exceed the temperature of the
control conductor. The temperature difference between the control conductor and the connector shall be
stable.
5.3.1

CCT temperature

The temperature of the connector tested by the Current Cycle Test method shall be stable between the
twenty-fifth (25th) cycle and the completion of the test.
5.3.2

CCST temperature

The temperature of the connector tested by the Current Cycle Submersion Test method shall be stable
between the tenth (10th) cycle and the completion of the test.
5.3.3 Stability determination for CCT and CCST
Temperature stability for the CCT and CCST tests is achieved if any temperature difference between the
control conductor and the connector, including allowance for measurement error, is not more than 10C
below the average of all temperature differences in the respective intervals defined in 5.3.1 and 5.3.2.
5.4

Mechanical tests

5.4.1

Tensile strength

The tensile strength of the connections tested in accordance with 8.0 shall be equal to or greater than the
values listed in 5.4.3.
5.4.2

Rated conductor strength

Rated conductor strength, as used in this standard, shall be determined in accordance with the applicable
ASTM standard listed in Annex B, or as furnished by the conductor manufacturer for nonstandard
conductors.
5.4.3

Tension

The tensile strength of the connector shall be equal to or greater than five percent (5%) of the rated
conductor strength of the weaker of the conductors being joined, but not less than the values in Table 2
or Table 3.

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Table 2 Tensile load, AWG Cable


Cable
Size
AWG
16
14
12
10
8
6
4
3
2
1

Pullout
Copper
N
133
222
311
356
400
445
623
712
801
890

lbf
30
50
70
80
90
100
140
160
180
200

Aluminum
lbf

200
222
311
356
400
445

45
50
70
80
90
100

Table 3 Tensile load, metric cable


Cable
Size
2

mm
1.5
2.5
4
6
10
16
25
35

Pullout
Copper
N
180
270
330
380
420
540
670
850

lbf*
40
60
75
85
95
120
150
190

Aluminum
N

lbf*

214
267
334
423

48
60
75
95

*For reference only


NOTEThese tables are to ensure mechanical performance for smaller wire sizes where the five percent (5%) minimum is not
adequate for long-term reliability.

5.5

Thermal performance of insulated system under load (ISUL)

5.5.1

Performance requirements for ISUL

Connectors shall be tested in accordance with 9.0 for one hundred twenty (120) hours and shall remain
stable between the seventy second (72nd) hour and the one hundred twentieth (120th) hour of test. The
connector temperature shall not exceed the conductor temperature by more than 10C throughout the
entire test.
5.5.2

Stability determination for ISUL

Stability is achieved if the change in connector temperature reading does not differ by more than 2C
from the change in input conductor temperature as measured in 9.0.

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5.5.3

ANSI C119.1-2006

Insulation

The insulation provided as part of the connector system shall show no visible evidence of deterioration
when thermal stability is reached.
5.6

Integrity of seal and connector insulation

When tested in accordance with 10.0, this test determines the connector system's ability to withstand
repeated handling during underground installation.
5.6.1 Insulation resistance
When tested in accordance with 10.2(2), the connector assemblies shall have an insulation resistance
greater than six (6) megohms.
The insulation resistance of the assemblies measured in 10.2(8), (13), and (15) shall be either:
a) greater than ninety percent (90%) of the value measured in 10.2(2) for resistances less than 1x103
megohms or
b) a minimum of 1x103 megohms for all other conditions.
The latter criterion applies because of the extremely high resistance values and the difficulty in
accurately reading analog meters at high resistance levels.
5.6.2 Dielectric withstand
The assemblies shall withstand the dielectric withstand tests specified in 10.2(3) and (16) without
breakdown.
5.6.3 Leakage current
The leakage current of the assemblies shall not exceed 1 milliampere when tested in accordance with
10.2(17).

Test Procedures, General

6.1

Test connectors

6.1.1

Description

A complete description of the test connectors, conductors, and inhibiting compound shall be included in
the test report.
6.1.2

Family sample set

To qualify a family of connectors (group of connectors using similar design criteria), a minimum of three
(3) sizes (largest, smallest and intermediate) shall be tested.
6.2

Test assembly methods

6.2.1

Installation details

All installation details, including methods and tools, not specifically defined or required in 6.0 through
10.0, shall be completely described in the test report.
6.2.2

Conductor preparation for electrical tests

The outer surface of the conductors in the contact area shall be mechanically cleaned using a wire brush
until the entire contact area of the conductor is clean.

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6.2.3

Conductor preparation for mechanical tests

The portion of the conductor that is to be inserted into the connector shall be wiped with a cloth coated
with particle-free petroleum jelly.
NOTEThis is to increase the severity of all mechanical tests.

If the connector is supplied with an inhibiting compound in the wireway, then no conductor preparation is
required on the portion of the conductor to be inserted into the connector.
6.2.4

Connector preparation

Connectors shall be prepared in accordance with the manufacturer's recommendations.


6.2.5

Connector installation

The methods and tools used to install the connector shall be in accordance with the manufacturer's
instructions.

Current Cycling in Air

7.1

Test assembly

(Refer to Figure 1 and to Annex C, Figure C.1 for suggested test loop diagrams.)
7.1.1

Conductors

Each connector shall be tested with the combination of input and output bare conductors, representing in
number, size, and arrangement the most severe heating condition for which the connector is designed.
The connectors shall be installed in their "as received" condition, which may include insulation. The
connector may be tested with or without the seals; the choice shall be stated in the test report.
If the connector is recommended for use between aluminum-to-aluminum and aluminum-to-copper
conductors, it shall be tested on both combinations.
7.1.2

Connectors

Four connectors of the same size and type are required for each combination of conductors, as
determined in 7.1.1.
7.1.3

Equalizers

To provide equipotential planes for resistance measurements and to prevent the influence of one
connector on another, equalizers shall be installed in stranded conductor on each side of each connector
in the current cycle loop. Equalizers are not required on solid conductors. Any form of equalizer that
ensures permanent contact among all the conductor strands for the test duration may be used.
7.1.3.1 Welded equalizers
A welded equalizer made from aluminum is recommended for aluminum conductors.
7.1.3.2 Compression sleeve equalizers
When the connectors to be tested are identical, a continuous piece of conductor may be used between
the connectors, with an equalizer in the center. If a compression sleeve is employed as an equalizer with
aluminum conductors, the conductor in the contact area of the equalizer should be prepared as in 6.2.2.
7.1.4

Conductor lengths

The exposed length of stranded conductor between the connector and the equalizer, or between the
connectors of solid conductors in the current cycle loop, shall be in accordance with Tables 4 and 5. The
conductor length in Tables 4 and 5 does not include the length within the connector or equalizer. In
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addition, where connector design permits, the conductor end shall project 12.7 mm (1/2 in.) beyond the
connector contact groove. The equalizers at each end of the current cycle loop shall be joined to the
power source with additional lengths of the test conductor to be not less than the lengths specified in
Tables 4 and 5.

Table 4 Conductor lengths for current cycle tests, AWG sizes


Conductor Type
Aluminum

Exposed length
Copper

Stranded

Solid

in.

in.

4/0 AND Below

2/0 and Below

0.3

12

0.6

24

Over 4/0 Through 750 kcmil

Over 2/0 through 500 kcmil

0.6

24

1.2

48

Over 750 kcmil

Over 500 kcmil

0.9

36

1.8

72

Table 5 Conductor lengths for current cycle tests, metric sizes


Conductor Type
Aluminum

Exposed length
Copper

Stranded

Solid

in.*

in.*

120 mm2 and Below

70 mm2 and Below

0.3

12

0.6

24

Over 120 mm2 through 380 mm2

Over 70 mm2 through 240 mm2

0.6

24

1.2

48

Over 380 mm2

Over 240 mm2

0.9

36

1.8

72

*For reference only

7.1.5

Control conductor

A control conductor, for determining test current, shall be installed in the current cycle loop (between two
equalizers for stranded conductors). The control conductor shall be the same type and size as the
conductor in the current cycle loop that will be at the highest temperature. The length of the control
conductor shall be twice that given in Tables 4 and 5.
7.1.6

Equivalent aluminum/copper conductors

At the manufacturer's option, the size of the control conductor may be determined by selecting from Table
6 or 7 the conductor in the current cycle loop that has the least test current for equivalent
aluminum/copper conductors.
7.1.7

Multiple control conductors

If the test loop includes different conductors, and a question arises as to which conductor causes the
highest temperature rise, a control conductor of each type is required. The test current shall cause the
higher temperature rise in one of the control conductors to meet the requirements of 7.5.

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7.2

Loop configuration and location

7.2.1

CCT method

The current cycle loop may be of any shape provided the location of thermocouples for the connectors
and the center of the control conductor are installed at the same elevation, with at least 203 mm (8 in.)
separation between conductors and located at least 305 mm (12 in.) from any exterior wall and at least
610 mm (24 in.) from the floor and the ceiling. An example of a vertical test configuration is shown in
Figure 1.

Figure 1 An example of a vertical test configuration


7.2.2

CCST method

The control conductor shall be installed on the same horizontal plane as the test connectors. During the
current-ON period, no part of the circuit shall be less than 200 mm (8 in.) above the surface of the chilled
water. At the beginning of the current-OFF period, the connectors and the control conductor shall be
submerged to a minimum of 100 mm (4 in.) below the water surface.

ANSI C119.1-2006

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Table 6 Suggested initial test current
to raise AWG control conductor temperature 100C
Aluminum

Copper

Conductor

Current

Conductor

Current

(AWG)

(Amperes)

(AWG)

(Amperes)

90

95

125

130

170

180

200

245

1/0

230

1/0

340

2/0

270

2/0

400

3/0

320

3/0

470

4/0

380

4/0

550

250 kcmil

410

250 kcmil

615

300 kcmil

450

300 kcmil

700

350 kcmil

525

350 kcmil

780

400 kcmil

600

400 kcmil

850

500 kcmil

725

500 kcmil

990

750 kcmil

950

750 kcmil

1300

1000 kcmil

1085

1000 kcmil

1565

Table 7 Suggested initial test current


to raise metric control conductor temperature 100C
Aluminum
Conductor

Copper
Current

Conductor

(mm )

(Amperes)

(mm )
10

105

16

100

16

145

25

135

25

195

35

170

35

245

50

225

50

330

70

270

70

400

95

345

95

505

120

405

120

600

150

450

150

700

185

550

185

795

240

700

240

970

300

805

300

1100

400

930

400

1300

500

1085

500

1565

Current
(Amperes)

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7.3

Ambient conditions

Current cycle tests shall be conducted in a space free from forced air currents or radiated heat striking
(directly or indirectly) any portion of the test loop during the current-ON period. The ambient temperature,
measured within 610 mm (2 ft) of the test loop at a location that minimizes the effect of thermal
convection, shall be held between 15C and 35C.
7.4

Test current

The current values in Tables 6 and 7 are the suggested initial test amperes for achieving the required
temperature rise in the control conductor, and were selected to simplify current selection during test
startup. The actual test current may need to be adjusted from these values to achieve the required
conductor temperature rise. The tables cover commonly encountered conductor sizes. Some
experimentation or extrapolation of the table values may be required for conductor sizes not shown. The
currents provided are not intended to suggest current values for use in actual service.
7.5

Temperature conditions

7.5.1

CCT temperature conditions

The current cycle test current shall be adjusted during the current-ON period of the first twenty-five (25)
cycles to result in a steady-state temperature rise on the control conductor of 100C to 105C over
ambient temperature for Class A. This current shall then be used during the remainder of the test
current-ON periods, regardless of the temperature of the control conductor.
7.5.2

CCST temperature conditions

The current cycle submersion test current shall be adjusted during the current-ON period of the first five
(5) cycles to result in a steady-state temperature rise on the control conductor of 100C to 105C over
ambient temperature for Class A. This current shall then be used during the remainder of the test
current-ON periods, regardless of the temperature of the control conductor.
7.6

Current cycle periods

Each test cycle shall consist of a current-ON and a current-OFF period. The time required to make
resistance and temperature measurements is not considered a part of the current-ON or current-OFF
time periods.
7.6.1

Current cycle-ON period

The current-ON time is determined by reaching and maintaining thermal stability in the connector.
Thermal stability is defined as not more than a variation of 2C between any two (2) of three (3) readings
taken at not less than 10 minute intervals. The length of the current-ON period shall not be less than that
listed in Table 8 or Table 9, depending on the size of the control conductor.

Table 8 Minimum current cycle periods for AWG control conductors


Aluminum

Copper

Current-ON Period
(Hour)

Up through 300 kcmil

Up through #4/0 AWG

1.0

Over 300 through 750 kcmil

Over #4/0 AWG through 500 kcmil

1.5

Over 750 kcmil

Over 500 kcmil

2.0

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Table 9 Minimum current cycle periods for metric control conductors


Aluminum

Copper

Up through 185 mm2

Up through 120 mm2

Current-ON Period
(Hour)
1.0

Over 185 through 400 mm2

Over 120 through 240 mm2

1.5

Over 400 mm
7.6.2

Over 240 mm

2.0

CCT current cycle-OFF period

Connectors tested by the Current Cycle Test (CCT) method shall cool in ambient temperature air. The
duration of the current-OFF period for connectors tested by the CCT method shall initially be the same as
the current-ON period. The duration may be reduced by forced air cooling after the first twenty-five (25)
cycles. With the manufacturer's concurrence, forced air cooling may be initiated during the current-OFF
period after the first (1st) cycle. The duration for the reduced current-OFF period shall be established by
adding five (5) minutes to the time required for the four connectors to reach ambient temperature.
7.6.3

CCST current cycle-OFF period

Connectors tested by the Current Cycle Submersion Test (CCST) method shall be immersed in still,
chilled water (5C 4C) within thirty (30) seconds of the start of the current-OFF period. The connectors
shall remain immersed in the chilled water for a minimum of fifteen (15) minutes after the temperature of
the connector is reduced to the temperature of the water. The connectors shall be removed from the
water before they are energized at the beginning of the next current-ON cycle.
7.7

Measurements

Resistance and temperature measurements shall be made according to Table 10, depending on the
choice of test method. When the number of measurement datums exceeds those specified in Table 10,
the measurements nearest each specified cycle shall be used to evaluate performance.

Table 10 Resistance and temperature measurement intervals


Current Cycle Test Method (CCT)

Current Cycle Submersion


Test Method (CCST)

25 30

57

45 55

8 12

70 80

18 22

95 105

28 32

120 130

38 42

160 170

48 52

200 210

58 62

245 255

68 72

320 330

78 82

400 410

88 92

495 505

98 102

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7.7.1

Resistance measurements

Resistance measurements shall be made at the end of a current-OFF period with all connectors thermally
stabilized at the room ambient temperature. Thermal stability is defined as not more than a variation of
2C between any two (2) of three (3) readings taken at not less than ten (10) minute intervals.
Resistance measurements shall be made across each connector, between potential points located either
on the equalizers a maximum of one conductor diameter from the edge adjacent to the conductor or at
the midpoint of a solid conductor. A direct current shall be used for these measurements. The
magnitude of the current selected shall not produce heating of the conductor that results in a noticeably
changing measurement value during the period of current application. The current magnitude shall be
sufficient to provide an accurate measurement above the noise threshold of the measurement
instrumentation. The period of current application shall be as short as possible to achieve an accurate
measurement. The applied test current shall be reported.
NOTETypically, the dc current is less than ten percent (10%) of the test current.

Ambient temperature shall be measured within 610 mm (2 ft) of the test loop at a location that minimizes
the effect of thermal convection. The ambient temperature shall be recorded at the time of each set of
resistance measurements. The resistance of each connector assembly shall be corrected from the
measured temperature to 20C. The corrected resistance values shall be used to evaluate the
performance of the connectors.
NOTEThe resistance values obtained shall be corrected to 20C using the following formula:

R20 = Rm / [1 + (Tm - 20)]


Where Rm is the measured resistance, Tm is the temperature (C) of the connector and is the resistance
variation coefficient with the temperature. This coefficient can be taken equal to:
=

3.93 X 10-3/C for copper

= 4.03 X 10-3/C for aluminum


NOTEThe values for the Resistance Variation Coefficient were derived from IEEE 837-2002, Standard for Qualifying Permanent
Connections Used in Substation Grounding.

7.7.2 Temperature measurements


Temperature measurements of the connectors, control conductors, and ambient air shall be made at the
end of the specified current-ON cycle, immediately before the current is turned off. The temperatures
shall be measured by means of thermocouples that have been permanently installed for the current cycle
tests. At least one thermocouple shall be installed in the current path of each connector at a point where
the highest temperature is anticipated. A suggested location for the thermocouples is shown in Annex D.
One thermocouple shall be installed at the midpoint of the control conductor.
7.8

Maximum number of current cycles

The number of cycles specified to complete the test may be extended to permit taking the final
measurements during normal working hours.
7.9

Evaluation interval

The evaluation of the connector performance, as specified in 5.2 and 5.3, shall be made on the basis of
resistance and temperature measurements.
7.9.1

Evaluation by the CCT method

The resistance and temperature measurements in accordance with 7.7 shall be used to evaluate
connectors tested by the Current Cycle Test (CCT) method.

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7.9.2

ANSI C119.1-2006

Evaluation by the CCST method

The resistance and temperature measurements taken in accordance with 7.7 shall be used to evaluate
connectors tested by the Current Cycle Submersion Test (CCST) method.

Tensile Strength

8.1

Test connectors

8.1.1

Number of samples

Three samples of each connector-conductor combination shall be subjected to each mechanical test
described in 8.2.
8.2

Pullout test

8.2.1 Pullout strength tests shall be performed on the following two conductor combinations for which
the connector is designed:
(1)

the highest rated tensile strength conductor, and

(2)

the smallest diameter conductor with the highest rated tensile strength.

8.2.2 When conducting the tensile strength test, care shall be taken to ensure that all strands of the
conductor are loaded simultaneously.
8.2.2.1 The load shall be applied at a cross-head speed not exceeding 20.6 mm per minute per meter
(1/4 in. per minute per foot) of the total length of the exposed conductor between jaws.
8.2.2.2 The length of the exposed conductor between each gripping means and each connector shall not
be less than 250 mm (10 in.).
8.2.2.3 The tensile strength shall be determined as the maximum load that can be applied. This load
shall be measured to an accuracy of five percent (5%) with instruments calibrated according to ASTM E4.
The mode of failure shall be recorded.
8.2.2.4 Minimum values indicated in 5.4.3 are required.

Thermal Stability of Insulated System Under Load (ISUL)

9.1

Test assembly

(Refer to Annex C, Figure C.2 for suggested test loop diagram.)


A minimum of two insulated connector systems shall be assembled in accordance with the
recommendations of the connector manufacturer, on the combination of insulated input and output
conductors that represents in number, size, and arrangement the most severe thermal condition for which
the connector is designed.
9.2

Test conditions

This test shall be conducted in a space free of forced air currents or radiated heat striking (directly or
indirectly) any portion of the test loop during the current ON period. The ambient temperature, measured
within 610 mm (2 ft) of the test loop at a location that minimizes the effect of thermal convection, shall be
held between 15C and 35C. The ambient temperature shall not vary more than 5C during the entire
test.

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9.3

Test current

The input current shall be adjusted to produce 90C + 5C on the hottest conductor.
9.4

Measurements

The temperature of the input conductor shall be measured under the conductor insulation at a point 305
mm (12 in.) from the connector. The temperature of the connector shall be measured under the connector
insulation in the current path between the input and output where the highest temperature is anticipated.
A suggested location for the thermocouples is shown in Annex D.
The temperature measurements shall be recorded a minimum of once every twelve (12) hours (plus or
minus two (+/-2) hours) beginning with the seventy-second (72nd) hour (plus or minus two (+/-2) hours)
and continuing through the one hundred twentieth (120th) hour.

10

Integrity of Seal and Connector Insulation

10.1

Assemblies for test

Two (2) connector assemblies with the largest insulation diameters and two (2) connector assemblies
with the smallest insulation diameters shall be tested in accordance with 10.2.
Each assembly shall be assembled in accordance with the manufacturer's recommendations.
10.2

Procedural sequence

Each connector assembly shall be subjected to the following in the order in which they are listed:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
10.3

Water immersion for twenty-four (24) hours in accordance with 10.3.


Insulation resistance measurement in accordance with 10.4.
Dielectric withstand test in accordance with 10.5.
Heat conditioning in accordance with 10.6.
Flex in accordance with 10.7.
Twist in accordance with 10.8.
Water immersion for twenty-four (24) hours in accordance with 10.3.
Insulation resistance measurement in accordance with 10.4.
Cold conditioning in accordance with 10.9.
Flex in accordance with 10.7.
Twist in accordance with 10.8.
Water immersion for twenty-four (24) hours in accordance with 10.3.
Insulation resistance measurement in accordance with 10.4.
Current cycle and water submersion in accordance with 10.10.
Insulation resistance measurement in accordance with 10.4.
Dielectric withstand test in accordance with 10.5.
Leakage current test in accordance with 10.11.

Water immersion for twenty-four (24) hours

All connector assemblies shall be immersed for twenty-four (24) hours in a tank that contains tap water at
a temperature of 25C 5C. All parts of the connector assemblies, except leads, shall be at least 305
mm (12 in.) below the surface of the water.

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10.4

ANSI C119.1-2006

Insulation resistance measurement

While each connector assembly is immersed in accordance with 10.3, the insulation resistance shall be
measured by applying a direct-current voltage of 500 volts or 1000 volts for one (1) minute, keeping the
length of the immersed conductor constant, and then determining the insulation resistance at the voltage
used. The total length of the immersed conductor with each connector assembly shall not exceed 1.83 m
(6 ft). The conductor polarity shall be positive.
If the tracking distance from the end of the conductor to the water surface is too short, a guarded circuit
(see Annex E) shall be employed.
10.5

Dielectric withstand test

While each connector assembly is immersed in accordance with 10.3 it shall be subjected to a 2.2-kV fifty
(50) or sixty (60) Hertz test voltage for one (1) minute, applied between the water and the conductor.
10.6

Heat conditioning

Each connector assembly shall be conditioned in an air-circulating oven at 90C 5C for seventy-two
(72) hours. After the conditioning period, the connector assemblies shall be allowed to cool to a room
temperature of 25C + 5C.
10.7

Flex

Each connector assembly shall be subjected to the following:


The insulated conductor shall be securely clamped at a distance from the joint as follows:
For conductors that are #4 AWG and larger, fifteen (15) times the diameter of the insulated
conductor.
For conductors that are smaller than #4 AWG (16 mm2), twenty-five (25) times the diameter of the
insulated conductor.
The connectors shall be bent ninety (90) degrees to one side, returned to the starting position, bent ninety
(90) degrees in the opposite direction, and returned to the starting position (see Figure 2). Each seal shall
be subjected to ten (10) such flexing cycles.
10.8

Twist

While clamped in accordance with 10.7, the connector shall be twisted around the conductor axis fifteen
(15) degrees in one direction from the starting position, returned to the starting position, twisted fifteen
(15) degrees in the other direction, and returned to the starting position (see Figure 2). Each connector
assembly shall be subjected to five (5) such twisting cycles.
Some bending is tolerated to allow both seals on one connector assembly to be twisted simultaneously.
10.9

Cold conditioning

Each connector assembly shall be exposed for a minimum of four (4) hours in air having a temperature of
-18C + 5C. Within five (5) minutes after removal from the cold conditioning, the assemblies shall be
tested in accordance with 10.7 and 10.8. Both tests shall be completed within the five (5) minute time
interval.
10.10

Current cycle and water submersion

The connector assembly shall be connected in series with a control cable identical in size and type to that
used in the connector assembly and then subjected to the following sequence of operations for fifty (50)
cycles:
1. Heating by current in air. The current-ON period shall be one (1) hour using sufficient
current to raise the temperature of the conductor of the control cable to 90C + 5C.
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2. The current shall then be turned off and, within three (3) minutes, the connector shall be
submersed in water having a temperature of 25C 5C for at least one half (1/2) hour.

10.11

Leakage current test

Following the dielectric withstand test mentioned in 10.2 (16) and, while still immersed in the water, the
connector assemblies are to be subjected to a six hundred (600) volt, fifty (50) or sixty (60) Hertz potential
between the water and conductor and the resulting leakage current measured.

11

Test Report

The test report shall include the necessary data to support conformance or nonconformance to the
requirements of this standard, and also the following:

Date of test

Description of all test assemblies

Description of connectors and inhibiting compound before testing to ensure traceability

Description of conductors, including rated conductor strengths

Description of connector installation procedure

Current cycle and current stability amperage

Description of the condition of connectors after testing

Name and location of the test facility and personnel conducting the tests

Test Method: CCT, CCST

All options used in performance of the test including the mounting method (drilled or surface
mounted) of the thermocouples. (Diagrams of test setup are desirable.)

Other pertinent information, such as installation details not specifically defined or required in
this standard.

Certification (if required)

12

Marking

12.1

Connector system marking

The principal component(s) of a connector system intended for direct burial or below grade use shall be
marked with the manufacturer's name or trademark, the catalog number and wire range. The marking shall
also be on the unit container (the smallest container in which the connector system is packaged).
12.2

Assembly instructions

Assembly instructions shall be provided with the connector system. The assembly instructions shall be
marked on the unit container or on an instruction sheet provided in each unit container. The assembly
instructions shall include, but are not limited to:
1. Manufacturers name, part number and wire range,
2. Wire connector assembly instructions (strip length, torque, tooling, etc.) and
3. Connector system assembly instructions.

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ANSI C119.1-2006

Note: H = distance determined in 10.7.

Figure 2 Flexing and twisting

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Annex A
(Informative)
Optional Tests to Meet the Requirements of UL 486D

If concurrent testing is being run to UL 486D, test sequences B, C, and D of UL 486D must also
be run.

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ANSI C119.1-2006

Annex B
(Informative)
Standards which are Applicable to C119.1 by Inference,
but Not Directly Referenced in the Standard
ASTM B8-86

Concentric Lay Stranded Copper Conductor, Hard, Medium Hard, or Soft

ASTM B8-99

Standard Specification for Concentric-Lay-Stranded Copper Conductors,


Hard, Medium-Hard, or Soft

ASTM B231/B231M-99

Standard Specification for Concentric-Lay-Stranded Aluminum


1350 Conductors

ASTM B400-01

Standard Specification for Compact Round Concentric-Lay-Stranded


Aluminum 1350 Conductors

ASTM B496-01

Standard Specification for Compact Round Concentric-Lay-Stranded


Copper Conductors

ASTM B784-01

Standard Specification for Modified Concentric-Lay-Stranded Copper


Conductors for Use in Insulated Electrical Cables

ASTM B786-02

Standard Specification for 19 Wire Combination Unilay-Stranded


Aluminum Conductors for Subsequent Insulation

ASTM B787/B787M-01

Standard Specification for 19 Wire Combination Unilay-Stranded Copper


Conductors for Subsequent Insulation

ANSI/ICEA S-81-570-2001

600 Volt Rated Cables of Ruggedized Design for Direct Burial


Installations as Single Conductors or Assemblies of Single Conductors

ANSI/ICEA S-105-692-2000

600 Volt Single Layer Thermoset Insulated Utility Underground


Distribution Cables

NEMA WC70-1999
/ICEA S-95-658

Non-Shielded Power Cables Rated 2000V or Less

UL 486 D

Insulated Wire Connector Systems for Underground Use or in Damp


or Wet Locations

UL 854

UL Standard for Safety Service-Entrance Cables Tenth Edition; Reprint


with Revisions Through and Including 11/13/2002

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Annex C
(Informative)
Test Loop Diagrams

Current Cycling Test Loop Diagram per 7.0


d

T1

(minimum) d

E1
E2

T2

E3

Tcc

Power
Supply

2d

E4

T4

T3

E5
E6
Figure C.1

Current cycle loop schematic for CCT and CCST tests, as outlined in 7.0 Current Cycling in Air. E
represents placement of equalizers on bare stranded, uninsulated cables. The minimum distance d
between connector and equalizers, and between equalizers and power supply, is specified in Tables 4
and 5. Except at the connector, adjacent cables and equalizers must be a minimum of twenty (20)
centimeters (eight (8) inches) apart to prevent thermal influences. Control Conductor is the length of
cable between equalizers E3 and E4 and Tcc is the control conductor temperature. Connector resistance
measurements are taken between successive equalizers, i.e., between E1 and E2, E2 and E3, etc. For
more precise thermocouple positioning for measuring connector temperatures Ti, see Annex D. In
addition to the five (5) temperature measurements indicated, the ambient air temperature is recorded, as
per 7.7.2.

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ANSI C119.1-2006

Thermal Stability of Insulated System Test Loop Diagram per 9.0

30 cm
(12 in)

Tc1

Ts1
Power
Supply
Ts2
Tc2
Figure C.2
Current cycle loop schematic for thermal stability of insulated system under load, as outlined in 9.0.
Connectors have seals fully installed, utilizing insulated cables. See Annex D for suggested
thermocouple positioning. In addition to the temperature measurements indicated, the ambient air
temperature is recorded. The distance between connectors and power supply should, at minimum, be
the distance specified in Tables 4 and 5 to minimize thermal interferences. Except at the connector,
adjacent cables and equalizers must be a minimum of twenty (20) centimeters (eight (8) inches) apart to
prevent thermal influences.

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Annex D
(Informative)
Suggested Thermocouple Locations

The locations shown are for illustration purposes only. Other locations may experience higher
temperatures. Determination of the highest temperature point should be made and the thermocouples
installed at that point.

Multiport Connector Test Setup

Figure D.1

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ANSI C119.1-2006

Splice Test Setup

Figure D.2

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Annex E
(Informative)
Guarded Circuit

Description

A guarded circuit is used to eliminate or to minimize the current flow between the insulation and
conductor ends, caused by surface leakage currents.

Setup

A typical setup to measure insulation resistance is to submerge the test conductor and sample in water
with both ends of the conductor exposed to air. Next, apply a test voltage between one exposed end of
the test conductor and the water (which serves as ground). Resistance is calculated by dividing the
known applied voltage by the measured current.
Applying a voltage between the conductor and water causes current to flow. The current may go two
ways, from the wire through the insulation to the water and from the exposed wire along the surface of
the insulation to the water. The latter is called surface leakage current. To eliminate or minimize the
surface leakage current from the measurement, create a guard by wrapping bare wire around the
insulation near the exposed conductor ends keeping the exposed conductor ends, along with the bare
wire, out of the water. The guards will capture or collect the current leakage along the insulation before it
reaches the water. Two methods may be applied as shown in figures E.1 and E.2.

Circuit Diagrams

Figure E.1
1) A = Ammeter

6) V = Voltage Source

2) I = Current Total; I = ISTRAY + IL

7) VG = Guard Voltage

3) IG = Guard Current

8) Figure E1, guard should be close to water, (no potential


between water and guard), and current measured in water circuit

4) IL = Leakage Current

9) Figure E1, shows VG to water is 0V.

5) ISTRAY = Current along Insulation

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ANSI C119.1-2006

Figure E.2
1) A = Ammeter

6) V = Voltage Source

2) I = Current Total; I = ISTRAY + IL

7) VG = Guard Voltage

3) IG = Guard Current

8) Figure E2, guard should be close to cable core, (no potential


between core and guard), and current measured in cable core circuit

4) IL = Leakage Current

9) Figure E2 shows 0V between core and guard

5) ISTRAY = Current along Insulation

25