Collection of SANS standards in electronic format (PDF)

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This standard is available to staff members of companies that have subscribed to the
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2. Indemnity

The South African Bureau of Standards accepts no liability for any damage whatsoever
than may result from the use of this material or the information contain therein,
irrespective of the cause and quantum thereof.

I agree with the above

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UDC 621-315.68 NRS 028:1993

ISBN 0-626-09404-6
First Edition

m CABLE LUGS AND FERRULES

0 For copper and aluminium conductors
h3
00
4 Preferred requirements for applications in the
Electricity Supply Industry
Cd

N R S
 This standard may only be used and printed by approved subscription and freemailing clients of the SABS.

This Rationalized User Specification is

issued by the NRS Project
on behalf of the
User Group given in the foreword
and is not a standard as contemplated in the Standards Act, 4993 (Act 29 of 1993).

Rationalized user specifications allow user

organizations to define the performance and quality
requirements of relevant equipment.

I l
Rationalized user specifications may, after a certain
application period, be introduced as national standards.

Amendments issued since publication

Amdt No. Date Text affected

Correspondence to be directed to Printed copies obtainable from

South African Bureau of Standards South African Bureau of Standards

(Electrical Engineering Standards) Private Bag X191
Private Bag X191 Pretoria 0001
Pretoria 0001
Telex: 32 1308SA
Fax: (012) 344-1568

COPYRIGHT RESERVED

Published in the Republic of South Africa

by the South African Bureau of Standards
1 Dr Lategan Road, Groenkloof, Pretoria
 This standard may only be used and printed by approved subscription and freemailing clients of the SABS.

NRS 028:1993

CONTENTS
Page

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Keywords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Normative reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5.1 Typetests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 Routine tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

6 Marking. labelling. packing and documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

6.1 Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.2 Labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.3 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.4 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Annexes

A Guide to purchasers on preparing an enquiry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

B Model form for schedules A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
C Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
 This standard may only be used and printed by approved subscription and freemailing clients of the SABS.

NRS 028:1993

Foreword

This specification has been prepared on behalf of a group of interested users for their use when
purchasing crimped cable lugs and ferrules for various applications. It is based on IEC specification
1238-1:1993.

This specification was prepared by a Working Group comprising the following members:

H D Perch (Chairman) Durban Electricity

C E Adams City of Port Elizabeth, Electricity Department (Obseyer)
R W Curtis JCI, for Chamber of Mines of South Africa (Observer)
F L U Daniel City of Cape Town, Electricity Department (Observer)
D P Desmet Genwest Industries
P de Ville City of Bloemfontein, Electricity Department
C Esprey Spoornet
L Gonsalves PWV Distributor Field Services, Eskom
R Groeneveld SABS
N S Harrison Mining & Services, Rand Mines (Observer)
P J R Johnstone Alusaf (Observer)
B E Kieser Johannesburg Electricity
C D Kruger lsco r
L D Meyer Eskom (Project leader)
I J Murray lscor (Observer)
R A Olsen Spoornet
G Travnicek Brown Boveri Technologies (Observer)
R A E van Develnter City of Pretoria, Electricity Department
N Visagie Siemens
C R Youens PWV Distributor Field Services, Eskom

A Manufacturers' Interest Group (MIG) was consulted on the contents of this specificijltion, and its
comments were incorporated where the Working Group was in agreement. The MIG comprised the
following members:

C M Coode Hycon Electrical Components

E Diepraam Stone-Stamcor
J A Koekemoer Electric Cable Accessories
D Machet Copper Tubing Africa (Pty) Ltd
R S E Martin Eberhardt-Martin
R W Miller Stone-Stamcor
R R Richmond Hardware Assemblies
B Stone MAKSAL Tubes
R A Wilks Stone-Stamcor

The Working Group was appointed by the Electricity Suppliers Liaison Committee (ESLC) which, at the
time of publication, comprised the following members:

S A Cilliers (Chairman) Distribution Technology Manager, Eskom

C E Adams City Electrical Engineer, Port Elizabeth, AMEU
A J Claasen Manager, Electrical Engineering Standards, SABS
R W Curtis JCI, for Chamber of Mines of South Africa
F L U Daniel City Electrical Engineer, Cape Town, AMEU
D F Hunt Corporate Technology Standardization Manager, Eskom
I P Kruger Director, Department of Electrical Engineering, SABS
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3 NRS 028:1993

A R Lock Director, Electrical Engineering, Johannesburg Electricity

J A Loubser City Electrical Engineer, Benoni, AMEU
K Mackay Electrical Engineering Manager, Generation, Eskom
A J Poulton Corporate Consultant, Distribution Technology, Eskom
C J Scherman City Electrical Engineer, Pretoria, AMEU
A J van der Mewe City Electrical Engineer, Bloemfontein, AMEU
H R Whitehead Executive Director, Durban Electricity, AMEU

Annexes A to C are for information only.

Recommendations for corrections, additions or deletions should be addressed to the NRS Project
Manager, c10 SABS, Private Bag X191, Pretoria, 0001.

Introduction

This specification was prepared to establish and promote uniform requirements for crimped cable lugs
and ferrules, used with crimping tools, for the terminating of cable cores and the joining of cable cores
for through connections.

The Electricity Suppliers Liaison Committee expresses the wish that, in the national interest and in
support of government policy to foster local manufacture and stimulate export, all purchasers adopt the
recommendations of this specification insofar as their particular conditions will permit. Any differences
between the requirements of this specification and the purchaser's requirements should, as far as
possible, be clearly indicated in the schedules attached to this specification and, where appropriate, be
submitted for consideration in future reviews of this specification.

Key words

Crimped lugs; Ferrules; Cable terminations and through connections; Specifications.

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NRS 028:1993

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 This standard may only be used and printed by approved subscription and freemailing clients of the SABS.

NRS 028:1993

SPECIFICATION

Cable lugs and ferrules for copper and aluminium conductors

Preferred requirements for applications in the Electricity Supply Industry

1 Scope
This specification details the characteristics of bare, crimped cable lugs and ferrules for use in the
terminating and jointing of solid, stranded, and multiple-stranded copper conductors of nominal cross-
sectional area from 1,5 mm2 to 1 000 mm2 and stranded and solid aluminium conductors of nominal
cross-sectional area from 16 mm2to 1 200 mm2.

This specification covers cable lugs for terminations and ferrules for through connections, suitable for
mounting on the conductors by compression, using special tools.

This specification is not applicable to pre-insulated lugs, or to compression joints for overhead
conductors which are designed to satisfy special mechanical requirements.

2 Normative reference

The following standard contains provisions that, through reference in the text, constitute provisions of
this specification. At the time of publication, the editions indicated were valid. All standards are subject
to revision and parties to purchase agreements based on this specification are encouraged to
investigate the possibility of applying the most recent edition of the standard listed below. Information
on currently valid national and international standards may be obtained from the South African Bureau
of Standards.

IEC 1238-1: l 993, Compression and mechanical connectors for power cables with copper or aluminium
conductors - Part 1: Test methods and requirements.

3 Definitions

For the purposes of this specification, the definitions given in IEC 1238-1:l993 shall apply, some of
which are, for convenience, given below:

3.1 barrel: The part of a connector into which the conductor to be connected is introduced.

3.2 compression jolnting; crimped jointing: A method of securing a connector to a conductor by

using a special tool to produce permanent deformation of the connector and the conductor.

3.3 connector: A device with a barrel or socket at one or both ends for connecting a conductor to an
equipment terminal or for connecting two or more conductors to each other.
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NRS 028:1993

3.4 ferrule: A connector for connecting two consecutive lengths of conductor.

3.5 joint: The assembly comprising the connector barrel and that portion of the conductor which has
been brought into intimate contact during the jointing process.

3.6 lug: A connector comprising a palm and a connector barrel, for connecting a conductor to an
equipment terminal.

3.7 palm: The part of a terminal lug used to make the connection to equipment terminals.

3.8 through connector: (see ferrule).

4 Requirements

NOTES
1 The type, size and other details of the cables to be terminated or connected, and the type and quantity
of lugs or ferrules required and the method of crimping will be specified in schedule A.

2 Details of the size of bolt hole and the bolt hole pattern that is required on all cable lugs, will be specified
in schedule A , to enable the supplier to provide a suitably sized palm.

4.1 Details of the manufacturer, the manufacturer's type or model number, the type of mbterials used,
a batch identifier, the major dimensions and other features of each connector to be supplied shall be
stated in schedule B.

4.2 The material of the connector shall be capable of withstanding, without deterioration, the normal
operating currents and, if so specified in schedule A, the short-circuit currents to which the electrical
system may be subjected. The material shall be of uniform quality and temper thrdughout each
consignment.

4.3 The material of the connectors shall be electrolytic copper, aluminium or aluininium alloy.
Electrolytic copper connectors may be bare or tinned. The materials used shall be stated in
schedule B.

4.4 Lugs and ferrules shall have a clean finish and be free of surface and internal defects such as
burrs, cracks, rolled seams, blisters, twists, press and chatter marks.

4.5 If so specified in schedule A, inspection holes shall be provided in the connector barrel(s), to
enable the user to check whether the conductor is fully inserted.

4.6 The flat faces of the palms of lugs shall be parallel and smooth.

4.7 The barrel of the connectors shall be marked with the nominal cross-sectional area of the
conductor to be crimped. Unless it is impracticable, this marking shall be positioned where it will not be
obliterated by the crimping.

4.8 Where a connector is used to join conductors of different materials, the bimetallic connector shall
be made of matching materials, bonded together by a suitable method, stated in schedule B, such as
friction welding, 10 ensure no loss of electrical conductivity and to prevent electrolytic corrosion.
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7 NRS 028:1993

4.9 Where a ferrule is used to join conductors of the same construction (e.g. PILCSWA cable to
PILCSWA cable), the barrels may interconnect.

4.10 Where cables of different construction are joined (e.g. PILCSWA cable to XLPE cable), the
barrels in the ferrule shall be separated by a barrier to prevent oil migration, e.g. from the PILCSWA
into the XLPE cable.

4.1 1 The bore of the barrel of connectors shall be profiled to facilitate conductor entry.
4.12 If so specified in schedule A, or if needed for the recommended crimping procedure, the barrel
sections of the connectors shall be marked to indicate the correct crimping position.

5 Tests

NOTE - A satisfactory cr~mpedtermination or through joint depends on the correct combination of the
connector, die and crimping tool suitable for each size and design (e.g. stranded, sector-shaped, compacted)
of conductor.

5.1 Type tests

5.1 -1 Type tests shall be performed in accordance with IEC 1238-1.
5.1.2 Type test certificates shall clearly state the make, type and size of conductor and the make, type
and size of lug or ferrule, as well as the make, type and size of die and crimping tool with which the lugs
or ferrules were connected to the conductors for the prescribed type tests.

5.1.3 If so specified in schedule A, type test results shall be provided for each type of connector
offered. Type tests on previous batches may be submitted if the materials and dimensions are identical
with those of the connectors being offered.

5.2 Routine tests

Checks for compliance with the manufacturer's standard dimensions shall be performed on each
production batch comprising 1 000 identical lugs or ferrules or more. The number of items subjected
to testing shall be 10 per 1 000 manufactured. If more than four items are not within the measured
tolerance, the sample batch shall be doubled and if more than eight items are not within measured
tolerance, the batch shall be reiected.

The routine tests performed, and the standard to which they were tested, shall be stated in schedule B.

6 Marking, labelling, packing and documentation

6.1 Marking
6.1.l All connectors shall be clearly identified to enable them to be traced back to the manufacturers.
Manufacturers may choose to provide additional information. Details of the marking and the positions
of the markings shall be stated in schedule B.

6.1.2 The palm of a lug shall De permanently marked on the non-contacting side.
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NRS 028:1993 8

6.1.3 Markings on the barrel of a lug or ferrule may be embossed on, or indented into, the surface.

6.2 Labelling

Unless otherwise specified in schedule A, labelling of boxes or of other packaging shall be in

accordance with the manufacturer's standard practice.

6.3 Packing

6.3.1 Unless otherwise specified in schedule A, the connectors shall be packed in standardized
packages, as chosen by the manufacturer.

6.3.2 If so specified in schedule A, the manufacturer shall state, in schedule B, holw aluminium
connectors will be packed to prevent surface corrosion during transportation and storage.

6.4 Documentation

If so specified in schedule A, the manufacturer shall provide documentation for each type of connector
supplied, detailing the correct die size and type, the recommended crimping tool(s) and hqw and where
to apply the crimps to ensure the correct joint between the conductor and the barrel.
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NRS 028:1993

ANNEX A
(informative)

Guide to purchasers on preparing an enquiry

A.l General

A model form is given in annex B to provide the purchaser with a convenient aid to purchasing. The
use of annex B is intended to obviate the need for preparing a detailed technical specification.

The purchaser need only specify compliance with NRS 028, provide the tenderers with details of his
particular requirements, and set out the information he requires the tenderer to provide, as indicated
below.

NOTE - It is assumed that tenderers are in possession of NRS 028.

A.2 Schedules

The model form in annex B provides the purchaser with examples of a schedule A and a schedule B.
In his enquiry, the purchaser should provide his own schedule A and schedule B, based on these
examples.

A.2.1 Schedule A

Schedule A lists the requirements to be specified by the purchaser in enquiries and orders. These
requirements include references to the relevant subclauses in the specification to assist in compiling the
schedules.

Where the text of any referenced standards stipulates that the purchaser shall indicate his requirements,
these requirements should also be specified in schedule A.

The purchaser should set out his particular requirements and choices in his own schedule A.

A.2.2 Schedule B

The purchaser should draw up his own schedule B (based on the schedule B in the model form), and
require the tenderer to fill in this schedule. By doing this, the tenderer will be stating compliance with
NRS 028 and will provide the information the purchaser has requested.

NOTES
1 Where NRS 028 allows the purchaser to make a choice, the example of schedule A (in the model form
in annex B) lists the preferred ~temslvalues/quantities. In the interests of standardization, purchasers are
encouraged not to deviate from these preferences.

2 When preparing his owr! schedule A and schedule B from the examples in the model form in annex B,
the purchaser need only include the items he considers to be relevant or necessary.

3 These schedules, when completed, become normative annexes to the enquiry specification.
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NRS 028:1993

A.3 Commercial conditions

A purchaser will furthermore need to indicate the commercial conditions applicable and dlaw up a price
schedule. Requirements for delivery, storage, packing and marking should be attended to in this part
of the enquiry.

A.4 Quality assurance

NRS 028 does not cover the purchaser's possible requirements in respect of quality assufance, quality
control, inspections, etc., since each purchaser needs to consider the criticality of the bpplication of
each component, his own policy towards these matters, etc. Purchasers are refebed to SABS
IS0 9001, SABS IS0 9002 and SABS IS0 9003 for guidance.

A.5 Testing

Attention should be paid to the subject of tests and the related costs. Tests should be oarried out by
a competent party and tenderers should be requested to provide assurances on this point. Price
schedules should be so drawn up and covering letters so worded that the costs of all sewices such as
tests, delivery and spares are declared and allowed for in the tender.

When samples are being tested for type and for routine tests, the number of sarnplesused in type
testing, and the Frequency of sampling tests should be agreed upon with the supplier.

A.6 Revision of standards used as normative references

NRS 028, as has been indicated, is based on a set of defined standards which may have been revised
or amended. It may be expecied that most purchasers would in principle wish to employ the latest
standards. It is recommended that an approach to this question be to secure an underbaking from a
supplier to review the latest versions and amendments and to incorporate these where possible and
agreeable to both parties. A blanket commitment to work to the "latest" versions of standards creates
risks for both parties and should be properly assessed. This invariably cannot be donb in the time
available. A blanket commitment to use the "latest" versions of standards creates legaldifficulties of
interpretation.
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NRS 028:1993

ANNEX B
(informative)

Model form for schedules A and B

Schedule A : Purchaser's specific requirements
Schedule B : Particulars of equipment to be supplied

4 5
Subclause Description Schedule A Schedule B
4 General
Type of cable(s) to be terminated or XXXXXXXXXX
connected XXXXXXXXXX
Method of crimping to be used XXXXXXXXXX

Note 1 Cable 1 :
a) Size of cable XXXXXXXXXX

b) Conductor material XXXXXXXXXX

XXXXXXXXXX

c) Construction of conductor(s) XXXXXXXXXX

d) Compaction of conductors XXXXXXXXXX

e) Shape of conductor(s) XXXXXXXXXX

Cable 2 (if applicable):

a) Size of cable XXXXXXXXXX

b) Conductor material XXXXXXXXXX

c) Construction of conductor(s) XXXXXXXXXX

d) Compaction of conductors XXXXXXXXXX

e) Shape of conductor(s) XXXXXXXXXX

Connectors
4.1 a) Manufacturer's name XXXXXXXXXX

b) Manufacturer's trademark XXXXXXXXXX

c) Manufacturer's model no. or type XXXXXXXXXX

reference and batch identification XXXXXXXXXX

4.2 a) Current rating

b) When relevant, fault current
Note 1 Lugs
Quantity of lugs required XXXXXXXXXX

4.3 a) lug material (1) barrel XXXXXXXXXX

(2) palm XXXXXXXXXX

4.1 b) barrel internal diameter

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NRS 028:1993

ANNEX B
(continued)

Subclause Description Schedule A Schedule B

cl barrel outside diameter

d) barrel length mm

e) palm length mm

f) palm width mm

g) palm thickness mm

Note 2 a) bolt hole diameter mm

b) bolt hole patlern See attached XXXXXXXXXX

sketch XXXXXXXXXX

4.5 Is an inspection hole required in lug barrel? Y ES/NO XXXXXXXXXX

or provided in the lug barrel? XXXXXXXXXX Y ES/NO

4.7 How is conductor size identified on the XXXXXXXXXX

barrel? XXXXXXXXXX

4.8 Method of bonding barrel to palm (if XXXXXXXXXX

bimetallic) XXXXXXXXXX

4.12 Are crimping positions required? XXXXXXXXXX

Are crimping marks provided? XXXXXXXXXX Y ES/NO

Ferrules

Quantity of ferrules required XXXXXXXXXX

Ferrule material 1 XXXXXXXXXX

Ferrule material 2 (if applicable) XXXXXXXXXX

4.1 Dimensions
a) barrel internal diameter (1) mm
(2) mm

b) barrel external diameter (l) mm

(2) mm

d) overall length mm

4.7 How is conductor size identified on the XXXXXXXXXX

barrel?
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NRS 028:1993

ANNEX B
(continued)

Subclause Description Schedule A Schedule B

- -

4.8 Method of bonding dissimilar barrels XXXXXXXXXX

4.5 Is an inspection hole required? Y ESINO XXXXXXXXXX

Is an inspection hole provided? XXXXXXXXXX Y ESINO

4.10 Is a barrier provided between the barrels? XXXXXXXXXX Y ESINO

4.12 Are crimping positions required? Y ESINO XXXXXXXXXX

Are crimping marks provided? XXXXXXXXXX Y ESINO

5.1 Type tests

a) Are type test results required with Y ESINO XXXXXXXXXX
tender?

b) Details of type test results available (to XXXXXXXXXX

IEC 20(C0)199:1991 XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX

5.2 Routine tests

Details of routine tests XXXXXXXXXX

6.1.1 Detail marking information provided on YES

connectors and positions of marking

6.2 Is packaging to be labelled in a specific NOISee XXXXXXXXXX

way? separate
sheet

Manufacturer's standard information on XXXXXXXXXX

label XXXXXXXXXX

Any other information on label

6.3.1 Are there any special requirements for NOISee XXXXXXXXXX

packaging? separate XXXXXXXXXX
sheet

6.3.1 Describe method of packaging to be used XXXXXXXXXX

XXXXXXXXXX

6.3.2 How are aluminium connectors packed? XXXXXXXXXX

XXXXXXXXXX
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NRS 028:1993

ANNEX B
(concluded)

Subclause Schedule A Schedule B

Are documents detailing crimping tool, dies, XXXXXXXXXX
etc., to be provided?

Details of documents provided for each XXXXXXXXXX

type of connector XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
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NRS 028:1993

ANNEX C
(informative)

Bibliography

The following documents, in addition to those listed in clause 2, were a source of reference in compiling
this specification. They do not constitute the provisions of this specification, but are referenced for
further information.

SABS IS0 900 1: 1987, Quality systems - Model for quality assurance in design/development,
installation and servicing.

SABS IS0 9002:1987, Quality systems - Model for quality assurance in production and installation.

SABS IS0 9003:1987, Quality systems - Model for quality assurance in final inspection and test.

sabs pta