Press cable lug, reducing sleeve, compression joint, pin joint and compression tap connectors

1 Purpose

The purpose of this document is to provide the necessary basis for the technical requirements to the compression cable lugs, reducing sleeves, compression joint, pin joints, compression tap connectors (C-clamps), compression terminals (E-clamps) and overhead contact wire splice in such a way that the production/building are controlled and delivered in accordance with the Bane NOR SF’s (BN) needs.

Requirements given in this document shall be followed when tendering components such as compression cable lugs, reducing sleeves, compression joint, pin joints, compression tap connectors (C-clamps), compression terminals (E-clamps) and overhead contact wire splice to BN’s overhead contact lines.

2 Scope

This specification deals with requirements to production and delivery of compression cable lugs, reducing sleeves, compression joint, pin joints, compression tap connectors (C-clamps), compression terminals (E-clamps) and overhead contact wire splice to BN’s overhead contact lines.

3 Function

Compression cable lugs and reducing sleeves are used to apply secure electric connection between cables and other components. Reducing sleeves and compression joint are used to apply secure electric connection between two cables, wires or lines. The purpose is to achieve the most effective conductivity and mechanical strength to resist vibration and disconnection. The component shall function as an adequate electric connection with characteristics in accordance with equivalent requirements to the cable, wire or line it shall be applied with.

4 Requirements

In this clause are the requirements to compression cable lugs, reducing sleeves, compression joint, pin joints, compression tap connectors (C-clamps), compression terminals (E-clamps) and overhead contact wire splice defined in three main sections.

• General requirements
  to compression cable lugs, reducing sleeves, compression joint, pin joints, compression tap connectors (C-clamps), compression terminals (E-clamps) and overhead contact wire splice
• Technical requirements
  to compression cable lugs, reducing sleeves, compression joint, pin joints, compression tap connectors (C-clamps), compression terminals (E-clamps) and overhead contact wire splice
• Documentation/tests
  to compression cable lugs, reducing sleeves, compression joint, pin joints, compression tap connectors (C-clamps), compression terminals (E-clamps) and overhead contact wire splice

If some general, technical or documentation/test requirements are increasing the costs compared with the tenders evaluation/assessment of the requirements utility, we request special response on this in accordance with the tender documentation.

4.1 General requirements to compression cable lugs, reducing sleeves, compression joint, pin joints, compression tap connectors (C-clamps), compression terminals (E-clamps) and overhead contact wire splice

4.1.1 Quality plan

The supplier should work according to a quality plan which satisfy ISO 9002 or equivalent. A copy of the quality manual shall be delivered to the BN with the tender. If subcontractors are used in the production or part production of compression cable lugs, reducing sleeves, compression joint, pin joints, compression tap connectors (C-clamps), compression terminals (E-clamps) and overhead contact wire splice it is the suppliers responsibility to control the subcontractors quality plan. BN shall be entitled to visit both the supplier and subcontractors and if required take a sample survey of the quality plan.

If the supplier finds divergence between descriptions in this document and drawings, the supplier shall make the BN aware of this in writing. In advance of production start such points shall be clarified and certified in writing.

Requirements specified in drawings plus requirements in documents which are referenced on drawings delivered by BN shall have precedent in front of this document.

4.1.2 Lifespan

Compression cable lugs, reducing sleeves, compression joint, pin joints, compression tap connectors (C-clamps), compression terminals (E-clamps) and overhead contact wire splice are to be produced for a service life of at least 50 years. If further action beyond specifications are necessary to achieve stated lifespan this should be stated and priced in the tender.

4.1.3 Environment, temperature and moisture

Compression cable lugs, reducing sleeves, compression joint, pin joints, compression tap connectors (C-clamps), compression terminals (E-clamps) and overhead contact wire splice shall be robust and reliable in all weather conditions and function within a temperature range stated in IEC 61238-1-3 and shall fulfil all requirements up to 100 % relative humidity. The supplier must specify limitations in use for the products that may have weaknesses in some environments. The supplier shall state this in their tender.

4.1.4 Dust and suspended solids (brake dust)

Compression cable lugs, reducing sleeves, compression joint, pin joints, compression tap connectors (C-clamps), compression terminals (E-clamps) and overhead contact wire splice shall independent of placement be in a way that it not reduces lifespan, function or performance.

4.1.5 Vibration

Compression cable lugs, reducing sleeves, compression joint, pin joints, compression tap connectors (C-clamps), compression terminals (E-clamps) and overhead contact wire splice shall have a suitable design such that vibration damages do not occure. If there is mechanical limitations with regards to vibrations, this shall be stated by the supplier.

4.1.6 Tools/special tools

On the basis of standardization BN do not want to use other types of hand press tool and hydraulic high pressure tool than ”Karl Pfisterer”. This means that compression cable lugs, reducing sleeves, compression joint, pin joints, compression tap connectors (C-clamps), compression terminals (E-clamps) and overhead contact wire splice shall be able to be mounted with the use of existing hand and hydraulic tools which to day are of the brand “Karl Pfisterer”.

The supplier are allowed the possibility of testing their products with BN’s pressure tools of the brand Karl Pfisterer. The achieved result must be document that the functionality and performance is ensured. A copy of the documentation included type tests with results shall be delivered to BN together with the tender. This has to be tested accordingly IEC 61238-1–3 and the particular norms/standards.

Requirements and restrictions to pressure tools shall be emphasized by the supplier for every single component type. The supplier shall compose a table with basis in scope of delivery on which type of Compression Dies that should be used.

4.1.7 Labelling

The components shall be labelled with code number for Compression Dies, trademark, type of material, cross section, pressure marking for hand and/or hydraulic pressure tool and pressure direction.

For compression tap connectors (C-clamps) are the connection between ordinary stranded conductor and flexible conductor of importance to have knowledge about. In ordinary stranded conductor are the cross section smaller than it is for flexible conductor. i.e. Cu 120 mm² stranded conductor are equivalent to Cu 150 mm² flexible conductor. The supplier should compose explanatory tables with this type of relations which should follow the description of range of application where this is relevant. Components that normally belongs together should be packaged together in plastic bags. The supplier shall state this in the tender.

The labelling should be easy visible and of such quality that it do not disappear or weakens the construction.

4.1.8 Storage and transport

There shall not appear damages on components during storage, handling and transport. Potentially limitations shall be stated by the supplier in the tender.

4.1.9 Recycling and destruction of components

The supplier shall in the tender state if there are environmentally damaging materials/substances in the products and if so how these should be handled both under use and by disposal of the product.

4.2 Technical requirements to compression cable lugs, reducing sleeves, compression joint, pin joints, compression tap connectors (C-clamps), compression terminals (E-clamps) and overhead contact wire splice

By contact between two different conductor materials in electric installations i.e. aluminium and copper it shall be taken special precautions. Pressure techniques and pressure components can not simply be applied on aluminium conductors. This due to among other factors:

1. The danger of corrosion on the boundary surface between aluminium and copper when moist is present
2. The two materials have different coefficient of thermal expansion
3. Compression Dies for copper shall not be used on aluminium

On selection of a correct pressure method and materials one must be able to achieve a good current transition with an optimal mechanical strength. This is of essential significance to restrained joints and anchoring.

Contact material shall be of the same material as the conductor the contact material should be mounted on, i.e. copper for copper conductors and aluminium for aluminium conductors. When aluminium conductors shall be connected with a copper bus bar there shall be used a bimetallic (friction welded) cable lug of a suitable alloy to prevent corrosion.

To avoid reactions between copper and galvanized poles at earthing points every type of cable lugs shall be sealed and tin-coated when used in this connection.

4.2.1 Compression tool

The supplier shall in their tender state if the components delivered/offered can be used in BN’s pressure tools of the brand “Karl Pfisterer”. This has to be documented with type tests. For more information see clause Tools/special tools.

4.2.2 Corrosion

The materials chosen shall be resistant to corrosion. Combinations that causes corrosion between different materials shall not occur. The supplier shall state the range of use. Corrosion characteristics shall be documented with tests form salt spray cabinet. This shall be verified by reports from the tests and copies delivered by the supplier with the tender.

4.2.3 Electric and mechanical requirements

4.3 Documentation/tests to compression cable lugs, reducing sleeves, compression joint, pin joints, compression tap connectors (C-clamps), compression terminals (E-clamps) and overhead contact wire splice

Technical data for Cu compression cable lugs:

• Material: E-Cu
• Norms: [DIN 46235]
• Copper conductor: [DIN 48201]
• Copper conductor: [DIN VDE 0295], rm, sm
• Sector formed conductor is circular formed by means of circular forming tool

Technical data for Al compression cable lugs:

• Material: AL
• Norms: [DIN 46329]
• Copper conductor: [DIN 48201]
• Copper conductor: [DIN VDE 0295], rm, sm
• Sector formed conductor is circular formed by means of circular forming tool

Technical data for bimetallic compression cable lugs [Al/Cu]:

• Follows DIN standards for Al and Cu
• Sector formed conductor is circular formed by means of circular forming tool
• Executed with connection splice in massive copper
• Fitted 240 mm² compressed annealed high voltage cable

Technical data for Cu Compression Joints, non-tension:

• Norms: [DIN 46267], Teil 1
• Copper wire: [DIN 48201]
• Copper conductors: [DIN VDE 0295], rm, sm

Technical data for Al Compression Joints, non-tension:

• Norms: [DIN 48085], Teil 3
• Aluminium wire: [DIN 48201]
• Aluminium conductors: [DIN VDE 0295], rm, sm, re, se
• Sector formed conductor is circular formed by means of circular forming tool
• Non-tension for Al-conductors: rm, sm, se, up to 12 kV

Technical data for Al reduction compression sleeves, non-tension:

• Surface: Bare
• Norms: [DIN 48085], Teil 3
• Aluminium wire: [DIN 48201]
• Aluminium conductors: [DIN VDE 0295], rm, sm, re, se
• Sector formed conductor is circular formed by means of circular forming tool

Technical data for Al/St Compression Joints, tension-proof:

• Materials:
  1. St-joint to no. 70 – 28/7 St 35 – 8/1 C15K
  2. Al-joint to no. 50 – 6/1 Al 99.5, from no. 70 – 6/1 AlMgSiIW
• Al/St compression joints: [DIN 48085]
• Feral wire: [DIN 48204]
• Tension-proof for splicing of feral wire

Technical data for bimetallic compression sleeves, non-tension:

• Materials
  
  1. Al 99.5
  2. E-Cu
• Follows DIN norms for Al and Cu
• Sector formed conductor is circular formed by the means of circular forming tool
• Non-tension design for splicing of Al- and Cu- conductor up to 12 kV

Technical data for Bz Compression Joints, tension-proof:

• Referes to Bz-wires in accordance with [DIN VDE 0115]
• Cross section 50 mm²
• Cross section 70 mm^²

Technical data for Al Pin Joints

• Materials: Al 99.5
• Norms: [DIN 48085], Teil 3
• Aluminium wire: [DIN 48201]
• Aluminium conductors: [DIN VDE 0295], rm, sm, re, se
• For Al-conductors: rm, sm, se
• Sector formed conductors is circular formed by the means of circular forming tool

Tecnical data for bimetallic Pin Joints:

• Materials
  1. Al 99.5
  2. E-Cu
• Follows DIN norms for Al and Cu
• For Al-conductors: rm, sm, se
• Sector formed conductors is circular formed by the means of circular forming tool
• Bimetallic pin joints adapted to 240 mm² compressed, annealed high voltage cable
• Al pin joints adapted to 240 mm² compressed, annealed high voltage cable

Tecnical data for Cu Compression Joints, non-tension, 12–30 kV:

• Materials: E-Cu
• Norms: [DIN 48085], Teil 1
• Copper wire: [DIN 48201]
• Copper conductors: [DIN VDE 0295], rm, sm
• Non-tension, for splicing of paper- or synthetic material insulated high voltage cable
• Carried out as hexagonal- or fully circular pressured

Tecnical data for Al Compression Joints, non-tension, 12–30 kV:

• Materials: Al 99.5
• Norms: [DIN 48085], Teil 3
• Aluminium wire: [DIN 48201]
• Aluminium conductors: [DIN VDE 0295], rm, sm, re, se
• Non-tension, for splicing of paper or synthetic material insulated high voltage cable
• Carried out as hexagonal or fully circular pressured
• Joints are designed with withe to prevent oil flow trough

Tecnical data for Al Compression Sleeves, non-tension, 12–30 kV:

• Materials: Al 99.5
• Norms: [DIN 48085], Teil 3
• Aluminium wire: [DIN 48201]
• Aluminium conductors: [DIN VDE 0295] rm, sm, re, se
• Non-tension, for splicing of paper or synthetic material insulated high voltage cable
• Carried out as hexagonal or fully circular pressured
• Sleeves are designed with withe to prevent oil flow trough

Tecnical data for Bimetallic Compression Joints, non-tension, 12–30 kV:

• Materials:
  1. Al 99.5
  2. E-Cu
• Follows DIN norms for Al and Cu
• Non-tension, for splicing of paper or synthetic material insulated high voltage cable
• Carried out as hexagonal or fully circular pressured
• Joints are designed with withe to prevent oil flow trough

Tecnical data for Cu H-Connector:

• Materials E-Cu
• Norms [DIN 48201] (i.e. adapted to DIN norms for Cu – wire)
• In H form for Cu conductors (e.g. among other things earthing grid in switching station)
• When branching 120 mm² and 150 mm² there are to be two connectors mounted
• H-Connector up to 25 mm² can be used for wire as well as single-wire conductor
• Sector formed conductors is circular formed by the means of circular forming tool

Tecnical data for Cu Compression Cable Lug:

• For use on Cu wire
• Materials: E-Cu
• Surface: Tin coated
• Norms: [DIN 46235]

Tecnical data for Cu C-Clamp:

• Materials: Cu
• Surface: Bare
• Norms: [DIN 48201]

Tecnical data for Cu Compression Tap Connector – tension-proof:

• Materials:
  1. Clamp E-Cu
  2. Clasp Bz
• Surface: Bare
• Norms: [DIN 48201], inwardly customized

Tecnical data for Cu Compression Terminal – tension-proof:

• Materials: Cu
• Surface: Bare
• Norms: [DIN 43141], customized to contact wire
• The compression terminal is used for branching from contact wire with cross sections between 80–120 mm² round and 8-shape profile in accordance with [EN 50149].
• To ensure god electrical connection and god mechanical strength there shall be mounted and pressured a clasp of bronze between the contact wire and the compression terminal.

Tecnical data for Contact Wire Splice, Riveted:

• Materials: Rivets Cu
• Clamping jaws: CuNiSi
• Surface: Bare
• Norms: [DIN 43141], customized to contact wire
• On contact wire that has reduced cross section due to e.g. mechanical damage the wire splice can be used as a reinforcement of the contact wire.

Tecnical data for Drilled Rail cable connection bonding system for signalling, return traction and earthing applications:

• Materials: Cu (tinned)
• Holes in rail: Ø19 mm
• Short circuit current I_k > 31.5 kA
• The drilled rail connections are to be submitted to an internal approval by BN before use if they have not been used by BN earlier and already have been approved.
• If approval is not obtained the components can not be used in BN’s infrastructure.

Tecnical data for Compression Suspension clamps for droppers Bz II 10/49, 50 mm² stranded wire, Ri 80/120 contact wire:

• Materials: Cu Ni2 Si
• Surface: Bare
• Compression joint: Bz 10 mm² 49 threads
• Stranded wire: Ø6.5–Ø12.6 mm
• Contact wire groove: 3.0–8.5 mm

4.3.1 Documentation

Required documentation on production/construction and volume of delivery shall be stored and archived by the supplier on a systematic way to ensure traceability between components and corresponding documents.

The supplier shall store documents on a suitable place for ten years. The documents shall be available to BN on request.

4.3.2 Material certificates

Materials shall fulfil requirements stated on the given drawings/catalogues. A copy of samples of material certificate shall be attached with the tender. These material certificates shall be be stored by the supplier and be available to BN on request.

4.3.3 Tests/control

The supplier shall compose suggestions to test procedures. These proposals shall be delivered together with the tender. The frequency of controls and the scope of tests/controls shall be accordingly relevant standards.

Template for routine/final inspection protocol shall be composed by the supplier and sent with the tender to approval by BN.

4.3.4 Documents

The following documents shall be stored by the supplier and delivered on request by BN

• Material certificates

The following documents shall be included in the tender

• Copy of the suppliers quality plan
• Procedures for routine tests/final inspection
• Templates for routine tests/final inspection protocol
• Samples of material certificates
• Copy of suggestion to list with which pressure methods and tools which guaranties an adequate execution
• Copy of type tests which shows that the supplier has tested their products with BN’s pressure tools of the brand “Karl Pfisterer” The achieved results must document that they verify the functionality and performance are adequate.
• Copy of requirements to maintenance of pressure equipment and procedures for this.
• Copy of assembling guide where this can be relevant (descriptions shall be in Norwegian, English can be accepted)
• Copy of maintenance manual where this can be relevant (descriptions shall be in Norwegian, English can be accepted)
• Copy of the clause Checklist in filled in state.
• Copy of the other documents required in this technical specification, check out each paragraph especially

If there are other relevant tests, norms or instructions etc. which are used and not mentioned in this specification, this shall be pointed out by the supplier together with the tender.

4.3.5 Drawings

The supplier shall deliver drawings/documentation mentioned below if this is not clearly described in DIN standards.

• Design drawings or catalogues with figures and technical details of compression cable lugs, reducing sleeves, compression joint, pin joints, compression tap connectors (C-clamps), compression terminals (E-clamps) and overhead contact wire splice
• Drawings shall be presented on paper or file format (dwg files) for control of technical measurements and details.

5 References

6 Appendix

6.1 Drawings

7 Scope of delivery

7.1 Fulfilment form for the supplier

7.1.1 Compliance list for components

7.1.2 Suggestions to test reports

7.1.3 Suggestion to spare parts

7.1.4 List of mandatory documentation

8 Checklist

The supplier shall sign out all points of the specification in the following checklist. Any deviation from these requirements shall be commented, which points a), b), c), etc., that are not met and what / why point is not fulfilled.