1.

Scope :
This specification covers the design, manufacture assembly and testing of
Accessories for Anchoring, suspending and making connections to Aerial
Bunched cables rated 1100 volts and insulated with cross-linked polyethylene.

2. Standard :

The design, performance and test requirements shall confirm to this specification
and the following standards. However in case of any conflict, the requirements of
this specification shall prevail

NFC 33-020 Insulation Piercing Connectors

IS 14255 LV Aerial bunched cables
NFC 33-209 LV Aerial Bunched cables
NFC 20-540 Environment Testing for Outdoor
NFC 33-004 Electrical Ageing Test

3. Climatic Conditions :

The equipments to be supplied against this specification shall be suitable for

satisfactory continuous operation under the following tropical conditions.
i) Peak ambient temperature : 60°C
ii) Minimum Ambient Temperature in shade : -5°C
iii) Maximum average ambient temp. in 24 hours period in shade : 50°C
iv) Maximum yearly weighted average ambient temperature : 45°C
v) Maximum temperature attainable by an object exposed to sun : 65°C
vi) Maximum relative humidity : 100 %
vii) Average number of thunder storm days per annum : 40
viii) Average number of rainy days per annum : 120
ix) Average annual rainfall : 900 mm
x) Number of months of tropical monsoon conditions : 4 Months
xi) Maximum wind pressure : 195 kg/m²
xii) Altitudes : Not exceeding 1000m

4. Cable data

The standard sizes and characteristics of the phase and street lighting conductors
shall be as per the table below :

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 Table – I
Dia of compacted Insuln Dia Over Insulation
Number
Area conductor Thkns
of
(mm sq) (mm) Min (mm) Max (
Strands Min (mm) Max (mm)
mm)
16 7 4.6 5.1 1.2 7.0 7.5
25 7 5.8 6.3 1.4 8.6 9.1
35 7 6.8 7.3 1.6 10.0 10.5
50 7 7.9 8.4 1.6 11.1 11.6
70 12 9.7 10.2 1.8 13.3 13.8
95 19 11.0 12.0 1.8 14.6 15.6
120 19 12.0 13.0 1.8 15.6 16.6
150 19 13.9 15.0 1.8 17.5 18.6

The standard sizes and characteristics of the messenger shall be as per the table :

Table – 2
Dia of compacted Insuln Dia Over Insulation
Number
Area conductor Thkns
of
(mm sq) (mm) Min (mm) Max (
Strands Min (mm) Max (mm)
mm)
25 7 5.8 6.3 1.4 8.6 9.1
35 7 6.8 7.3 1.6 10.0 10.5
50 7 7.9 8.4 1.6 11.1 11.6
70 12 9.7 10.2 1.8 13.3 13.8
95 19 11.0 12.0 1.8 14.6 15.6

5. Basic Features

The Accessories for LT XLPE Insulated Aerial Bundled Conductors (ABC) with
insulated messenger cum neutral are specified below.

5.1. The ABC accessories should be of proven design with minimum 5 years
record of satisfactory operation with a major utility. Order copies and
performance Certificates should be enclosed with the offer.

5.2. Since ABC accessories are to be used with insulated neutral-cum-messenger,

their design should incorporate specific features to prevent damage to the
insulation while meeting the required electrical, mechanical & thermal
requirements.

5.3. All mechanical, electrical & thermal ratings should meet or exceed 90% of the
corresponding ratings of the cable, or the values specified herein, whichever
are more stringent.

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 5.4. The accessories should provide “Double Insulation” so that a single point
failure of insulation will not result in the system tripping.

5.5. The Accessories should be manufactured by a company registered under ISO

9001 : 2000 certification system.

6. The ABC accessories shall include :

6.1. Insulation Piercing Connectors :for making tap-off/branch connectors

to an ABC.

7. Insulation Piercing Connectors :

7.1.1. Insulation Piercing Connectors (IPC) are used for making Tee or Tap-off
connectors to an ABC.

7.1.2. Insulation Piercing Connectors are designed to make a connection

between the uncut main conductor and a branch cable conductor without
having to strip either cable to expose the conductor instead the tightening
action of the IPC will first pierce the Insulation, then make good electrical
contact between the main end and branch conductor while simultaneously
insulating and sealing the connection.

7.1.3. The connectors shall be suitable for use with the following sizes of
cables :

Connector Type Main Cable Size Branch Cable Size Range

range
Type 1 6-50 sq mm 2.5 -25 sq mm
Type 2 10- 150 sq mm 6-50 sq mm
Type 3 35 – 150 sq mm 35-150 sq mm

8. Constructional features.

8.1.1. The housing shall be made entirely of mechanical and weather resistant
plastic insulation material and no metallic part outside the housing is
acceptable except for the tightening bolt.

8.1.2. Any metallic part that is exposed must not be capable of carrying a
potential during or after connector installation.

8.2. Screws or nuts for fitting IPC must be fitted with torque limiting shear heads to
prevent over tightening or under tightening. (Min & Max Torque values to be
specified by manufacturer.) Tightening by digital Torque wrench using the
timing and steps mentioned in NFC 33-020 shall be acceptable in place of
tightening by torque motor.

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 8.2.1. The IPC must perform piercing and connection on Main and Branch
cable simultaneously.

8.2.2. The IPCs shall be water proof and the water tightness shall be ensured
by appropriate elastomer materials and not by grease, gel or paste alone.

8.2.3. Design of IPC should be such as to not cause damage to insulation of

adjacent conductors due to vibration and relative movement during
service.

8.2.4. The connector shall have a branch cable end cap which can be slide
fitted onto the main connector body on either right or left by the installer
(depending on site requirement) for sealing the cut end of the branch
cable. Once the connector is fitted, it should not be possible to remove the
cap without opening the connector.

9. Mechanical tightening and Electrical Continuity.

9.1. Connectors shall be tightened upto 70% of the minimum torque indicated by
the manufacturer. At this torque electrical contact should have occurred
between the conductors to be joined.

9.2. At 1.5 times the maximum torque indicated by the manufacturer, there shall be
no breakdown of any part of the connector or the conductors. (After shear
head breakage, further tightening to be done by suitable means)

9.3. Maximum rated torque shall not exceed 20 N.m for conductor < 95 sq.mm. and
30N.m for >95 but < 150 sq.mm.

9.4. Tightening screws shall have hex. Heads of 10mm 13mm or 17mm only.

10. Effect of tightening on Main Core.

10.1. The connector shall be fitted approx. at the center of the main core,
which is secured between two anchoring points 0.5mtr. to 1.5mtr. apart. At the
time of fitting the connectors, the main core shall be under longitudinal tension
at 20% of the load indicated in Table 7

Table – 7
Nominal Cross – section Tensile Strength (Newton)
(mm. Sq.)
16 1200
25 1800
35 2500
50 3500
70 5000
150 10000

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 10.2. Tensile strain shall be increased to the full value indicated in the Table 7
and held for 1 minute. There should be no breakdown of the core conductor.

11. Effect of tightening on Branch Core.

11.1. Test specimen shall be made up as in clause 4.3.1 except that this shall
be done on the smallest cross sections of main and branch conductors within
its range.

11.2. An increasing tensile load shall be applied to the Branch Conductor

along the axis of the recess for the Branch cable. Load shall increase at 100 –
500 N/minute until it reaches the value specified in the Table 8 and maintained
for 1 minute.

Table – 8
Nominal Cross – section Tensile Strength (N)
(mm. Sq.)
16 (Alu) 290
25 450
35 & above 500

11.3. No slippage or breaking of conductor shall occur.

12. Dielectric & Water tightness Test.

12.1.1. The connector is tightened up to the minimum torque indicated by

the manufacturer.

12.1.2. Connectors are mounted on

12.1.2.1. Minimum cross section of main core.
12.1.2.2. Maximum cross section of main core.
12.1.3. In each case Branch is of minimum cross section.

12.1.4. Protection caps for the branch cable are to be used in accordance
with the requirements of clause 4.1.7. An additional water tight cap of any
design may be used to seal one end of the main cable if it is immersed
under water. No additional gel or any protection is to be provided while
installing connector.

12.1.5. The entire assembly shall be immersed at a depth of aprox. 30

cms. for 30 minutes with the free ends of main and branch cable out of the
water.

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 12.1.6. An ac voltage of 6 KV shall be applied between the water bath
and each of the cores in turn for 1 minute. There shall be no flashover or
electrical tripping with a trip setting of 10 mA + 0.5mA.

13. Electrical, Ageing Test.

13.1.1. Two test configurations are used according to table 9 with the
connections tightened to the minimum torque specified by their
manufacturers and resistance recorded.

Table – 9
Configuration Main core cross Branch core
section cross section
Tensile Strength
(K.N)
1st Configuration maximum Maximum
2nd Configuration Minimum minimum

13.2. The configurations are subjected to 200 heat cycles by injecting suitable
current into them. In each cycle the temperature of the conductor shall be
raised from ambient to 120 + 50C as measured by a thermocouple.

13.3. The duration of each heating cycle is chosen to maintain a sufficiently

steady temperature of 120 + 50C for 15 minutes. The duration of each cooling
cycle is chosen to bring the conductor temperature to within 20C of ambient.

13.4. Nominal heating current is indicated in the table 10. It shall be

permissible accelerate the temperature rise by using a current up to 1.5 times
the nominal current and to accelerate the cooling period by use of a fan or air
blower.

Table – 10
Configuration Cross – Nominal Heating Current
section (mm. Sq.) (A)
16 102
25 139
35 175
50 225
70 283
95 350
120 412
150 480
185 545
240 670

13.5. The over current test of clause 14 shall be done after 50 cycles if the
connector is a safety connector designed to ground a phase connector while
the line is being worked on.

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 13.6. At the end of the 200 cycles, the resistance shall again be measured. It
shall not differ from the initial value by more than 12%.

14. Over Current Test :

14.1.1. Over current test is required to establish the performance of
Safety Connectors that are intended to provide a safe path to ground for
the phases while the line is de-energised for working. It establishes the
performance of the connector under short term over load conditions.

14.1.2. After the first 50 cycles of clause 4.7, the connectors are
subjected to 4 over currents of 1 sec duration each.

14.1.3. The conductor temp at the start of the over current test should be
not more than 350C.

14.1.4. Current density during over current shall be 100 A/mm. Sq. for
aluminium and 95 A/mm. Sq. for Al. Alloy conductor.

14.1.5. Variation in time of over current is permissible between 0.85 sec

& 1.15 sec provided if maintains the relationship I2t = K where

I = rms value of over current in Amps.

T = time in seconds.
K = Constant.
14.1.6. After the over current test the electrical ageing test of clause 4.7
shall be resumed.

15. Type Test Reports

15.1. Type Test Reports should be submitted from an NABL Laboratory of

Repute or the NABL reciprocally accredited Works Laboratory in case of a
foreign manufacturers covering the following (on any convenient size of fitting
of same design made from the same materials).
15.2. The installation of the connectors shall be done by the laboratory
following Instructions provided by the manufacturer. The Test report shall
record the embossing and marking on the connector.

15.2.1. The following shall constitute Type Tests for IPC

15.2.1.1. Electrical Ageing Test
15.2.1.2. Dielectric and Water Tightness Test.
15.2.1.3. Mechanical Tightening Test
15.2.1.4. Effect of Tightening on main Core
15.2.1.5. Effect of Tightening on Branch core
15.2.1.6. Overcurrent Test (if applicable)

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16. Acceptance Tests

The following shall constitute acceptance tests For Insulation Piercing

Connectors:
16.1.
16.1.1. Visual *
16.1.2. Dimensional (as per SCD and Overall dimensions submitted with
tender offer) *
16.1.3. Electrical Ageing Test ***
16.1.4. Dielectric and Water Tightness Test. **
16.1.5. Mechanical Tightening Test **
16.1.6. Effect of Tightening on main Core **
16.1.7. Effect of Tightening on Branch core **

The above tests are to be carried out as per sampling plan below. However electrical
ageing test on IPC (marked *** ) is to be done on only one connector of each type and
size.

In case of random failure/defect, double the sample lot is to be drawn and there
should be no failure/defect exceeding half the permissible defects (rounded down)
shown in the chart.

For tests Marked * For Tests Marked **

Lot Size Sample Max Sample Max
Size permissible Size permissible
Defects Defects
Upto 100 2 nil 2 nil
101 to 1000 6 nil 4 nil
>1001 0.01 % 0.1 % of 4 nil
subject to pieces
min 6 checked
pieces

G A Drawings etc.

6.0.0 A drawing / picture clearly showing principal parts & dimensions for all products
should be submitted along with the offer.
6.1.0 The principal outer dimensions of each item , l x b x w in mm and weight in gms
should be submitted along with the offer
6.2.0 The Purchaser may call for samples for verification & evaluation purposes.

7.0 GTP
The Guaranteed Technical Particulars should be filled up in the enclosed
Annexure.

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8.0 Offers without required GTP, Type Test reports, Drawings, Dimensions, and
Copies of Purchase Orders and Experience Certificates are liable to be
ignored as incomplete / non-conforming offers.

CE/P&D CE/MM CE/Commercial SE/P&D

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 GUARANTEED TECHNICAL PARTICULARS FOR
AERIAL BUNDLED CABLE ACCESSORIES
Sl. No. Particulars
1. Name of Tenderer
2. Name & Address of Manufacturer of
ABC Accessories
3. a) Is Manufacturers ISO 9001 –
2000 Certificate enclosed
b) Is type test from NABL
accredited Lab
c) Are GA drawings enclosed?
d) Are experience certificates
enclosed?
4.0 Insulation Piercing Connectors (provide info separately for each size
offered)
Type Number & Size Range
4.1 Is any metallic part carrying potential
in operation exposed during
installation ?
4.2 Are end caps for branch cable ?
a) Slide on Type
b) Not removable after connector
fitting
4.3 Are torque limiting shear heads
provided on tightening bolts?
4.4 Range of sizes accommodated for
Branch & Main (fill 4.5.1 to 4.7.5 for
each size of connector)
4.5.1 Rated tightening torque (N. mtr.)
4.5.2 Min Shear head breaking torque (N
Mtr)
Max Shear head breaking torque (N
Mtr)
4.6.2 Max. Tensile load for no breakdown
of main conductor (for each cross-
section). Kg.
4.6.3 Max. tensile on Branch conductor for
no slippage / break Kg.
4.7 Voltage withstand under water
immersion
4.7.1 Is electric ageing test report
enclosed?
4.7.2 Number of cycles
4.7.3 Max. temp in each cycle (deg. C)
4.7.4 Max Resistance change during test
(%)

SE/P&D,
DHBVN, Hisar

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Additional requirements for Satellite connectors

1. This specification describes the features & technical requirements of Satellite

Connectors which are a version of Insulation piercing connectors used for
connecting an LT AB cable to service lines or branch cables.

2. The Satellite connector must meet all the General requirements, Type test and
Acceptance Test requirements for Insulation piercing connectors described
earlier, except as modified by this specification.

3. A Satellite connector is used for connecting one main cable of 25 to 95 sq mm to

multiple branch or service cables of size 2.5 to 35 sq mm.

4. The connection to the Main cable is achieved by piercing and resealing of the main
cable insulation by a set of teeth with suitable rubber pads, the piercing force being
controlled by a torque control shear head which forms part of the connector.

5. The branch /service cable connections are to be made after stripping the end of
the cable, and not by piercing of the insulation. The Satellite connector must have
provision of 4 outgoing branch circuits, as described in the Bill of qtys.

6. The outgoing circuits from the satellite should be independently and individually
connectable/ disconnectable without disturbing the connection to the main cable.

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