CLASS PROGRAMME Type approval DNVGL-CP-0409 Edition January 2018 Terminal lugs for LV power cables with aluminum conductors The content of this service document is the subject of intellectual property rights reserved by ("DNV GL"). The user accepts that it is prohibited by anyone else but DNV GL and/or its licensees to offer and/or perform classification, certification and/or verification services, including the issuance of certificates and/or declarations of conformity, wholly or partly, on the basis of and/or pursuant to this document whether free of charge or chargeable, without DNV GL's prior written consent. DNV GL is not responsible for the consequences arising from any use of this document by others. The electronic pdf version of this document, available free of charge from http://www.dnvgl.com, is the officially binding version.
FOREWORD DNV GL class programmes contain procedural and technical requirements including acceptance criteria for obtaining and retaining certificates for objects and organisations related to classification. January 2018 Any comments may be sent by e-mail to rules@dnvgl.com This service document has been prepared based on available knowledge, technology and/or information at the time of issuance of this document. The use of this document by others than DNV GL is at the user's sole risk. DNV GL does not accept any liability or responsibility for loss or damages resulting from any use of this document.
CHANGES CURRENT This is a new document. Changes - current Class programme DNVGL-CP-0409. Edition January 2018 Page 3
CONTENTS Changes current... 3 Section 1 General...5 1 Introduction...5 2 Documentation...5 Contents Section 2 Product requirements...7 1 Design requirements...7 2 Test requirements...7 Changes historic...9 Class programme DNVGL-CP-0409. Edition January 2018 Page 4
SECTION 1 GENERAL 1 Introduction 1.1 Objective The objective of this class program (CP) is to describe the type approval (TA) scheme for terminal lugs for LV power cables with aluminum conductors for voltages 0,6/1 kv and 1,8/3 kv. Section 1 For a description of the Society's type approval scheme in general and further information on general conditions and procedures for obtaining the Society's TA certificate, see the Society's document DNVGL- CP-0338 Type approval scheme. The procedures and requirements described in this CP are applicable for obtaining DNV GL TA certificate based on requirements given in: DNVGL-RU-SHIP Pt.4 Ch.8 Electrical installations DNVGL-OS-D201 Electrical installations. Guidance note: This class program is not applicable for obtaining EU marine equipment directive (MED) certificates. Visit www.dnvgl.com for information on MED certification. ---e-n-d---o-f---g-u-i-d-a-n-c-e---n-o-t-e--- 1.2 Scope This CP gives a description of the procedures and requirements related to documentation, design and type testing applicable for TA of terminal lugs for LV power cables with aluminum conductors. TA is based on compliance with design requirements given in the rules and/or other regulations and standards. The CP describes the applicable design requirements and how to document compliance with the requirements in order to obtain a TA certificate for the equipment. This includes, where relevant, technical requirements for how the type tests shall be performed. 1.3 Application DNV GL rules DNVGL-RU-SHIP Pt.4 Ch.8 require that terminal lugs for LV power cables with aluminum conductors are type approved by the Society. Low voltage power cables with aluminum conductor and cable lugs may be type approved for the following cross sectional areas: 70, 95, 120, 150, 185, 240 or 300 mm 2. A TA certificate in accordance with this CP will confirm compliance with the requirements in the rules as specified in [1.1]. The TA certificate will not confirm compliance with requirements in other parts of the rules. In case additional requirements in other parts of the rules shall be covered by the TA certificate, this shall be specified in the application for TA and will be stated in the TA certificate. 2 Documentation For TA of terminal lugs for LV power cables with aluminum conductors the following documentation shall be submitted: 1) data sheet(s) 2) drawings of all constructions covered by the type approval 3) reference to design standard DIN 46329 (compression terminal lugs only) or manufacturers specification 4) specification of applied materials 5) test results (from tests already carried out, if any) Class programme DNVGL-CP-0409. Edition January 2018 Page 5
6) applicant's proposal to type test and routine test 7) documentation of reliability and endurance onboard ships and mobile offshore units, if any 8) special operational limitations 9) list of the terminations covered by the type approval giving the following information for each variant: conductor cross section (mm 2 ) and number of strands conductors: class 2 or class 5 conductor shape: round or sector shaped 10) special properties, if any (watertight, fire resistant, etc.) 11) test program according to IEC 61238-1 Class A and additional tests in Table 1 12) application for type approval form TAA 901. Section 1 Class programme DNVGL-CP-0409. Edition January 2018 Page 6
SECTION 2 PRODUCT REQUIREMENTS 1 Design requirements Compression terminal lugs for LV power cables with aluminum conductors shall be designed according to DIN 46329. Mechanical terminal lugs may be designed according to manufacturer's specification. For both compression and mechanical lugs types the following applies: Terminal lugs shall be suitable for aluminum conductors complying with IEC 60228 class 2 or ISO 6722-2 class 5. Terminal lugs shall be suitable for cross sectional area 70, 95, 120, 150, 185, 240 or 300 mm 2. Terminal lugs shall have metric dimensions and hole size. Terminal lugs shall be made of material suitable for direct connection to copper bus bars. Terminal lugs shall be marked with manufacturer identification. Terminal lugs shall be supplied with heat shrink tubing with hot melt glue. Terminal lugs shall be water tight. Terminal lugs shall be supplied with complete assembly procedure. Section 2 For compression lugs the following applies: Terminal lugs shall be supplied with complete assembly and crimp procedure. Die size shall be embossed during crimping. 1.1 General requirements shall comply with the relevant requirements of the following publications in its latest edition including amendments: IEC 61238-1 Compression and mechanical connectors for power cables for rated voltages up to 30 kv (Um = 36 kv). Part 1: Test methods and requirements DNVGL-CG-0339 (relevant parts only as per Table 1). 1.2 Special requirements During installation all terminal lugs shall be properly sealed with heat shrink tubing with melt glue in order to prevent moisture to penetrate into terminal lug. This is important to avoid corrosion and risk of bad electrical connection creating voltage drop and overheating. 2 Test requirements 2.1 General complete testing according to IEC 61238-1 Class A water tightness test before and after installation vibration test according to DNVGL-CG-0339 salt mist test according to DNVGL-CG-0339 after pull out test according to IEC 61238-1 item 7.1 and additional destructive test until break shall be performed. Class programme DNVGL-CP-0409. Edition January 2018 Page 7
2.2 Visual inspection The products shall be visually inspected for good workmanship, conformity with the manufacturers drawings and specifications. All terminations shall be free of fractures, irregularities, sharp edges and damages in the surface. 2.3 Electrical/mechanical/environmental tests Section 2 Table 1 Required tests and test sequences Group of test samples Test Test standard Notes/acceptance criteria All Verification of correct fitting of all produced test samples As per manufacturer's instructions Visual inspection and dimensional checks on randomly selected samples 1 Water tightness test As per manufacturer's instructions Air with overpressure 0,5 bar sall be applied to both new and installed cable lugs, which are submerged in water. No air leak/bubbles shall be seen 2 Pull out force IEC 61238-1 item 7.1 For information: Each required test to be followed by destructive test until break. Tensile strength at break to be recorded Initial electrical resistance IEC 61238-1 item 6.2.1 First 200 heat cycles under current IEC 61238-1 item 6.3.1 to 6.3.4 3 Short circuit test Class A IEC 61238-1 item 6.3.4 Electrical resistance shall be measured before and after short circuit test Last 800 heat cycles under current IEC 61238-1 item 6.3.1 to 6.3.4 Electrical resistance shall be measured after 250 cycles and then every 75 cycles (totally 14 measurements) Final electrical resistance IEC 61238-1 item 6.2.1 Initial electrical resistance IEC 61238-1 item 6.2.1 4 Vibration test DNVGL-CG-0339 Sec.3 [6] Final electrical resistance IEC 61238-1 item 6.2.1 Initial electrical resistance IEC 61238-1 item 6.2.1 5 Salt mist test DNVGL-CG-0339 Sec.3 [10] Final electrical resistance IEC 61238-1 item 6.2.1 For each series of tests six (6) cable lugs shall be fitted in accordance with the manufacturer's instructions. Class programme DNVGL-CP-0409. Edition January 2018 Page 8
CHANGES HISTORIC There are currently no historical changes for this document. Changes historic Class programme DNVGL-CP-0409. Edition January 2018 Page 9
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