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ANSI C119.1-2006
Published by:
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.
i
ANSI C119.1-2006
ii
ANSI C119.1-2006
Contents
Page
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ANSI C119.1-2006
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ANSI C119.1-2006
Figures
1 An example of a vertical test configuration 8
2 Flexing and Twisting ....................................................................................................17
v
ANSI C119.1-2006
Tables
1 Test duration ..................................................................................................................2
2 Tensile load, AWG cable ...............................................................................................4
3 Tensile load, metric cable ..............................................................................................4
4 Conductor lengths for current cycle test, AWG sizes ....................................................7
5 Conductor lengths for current cycle tests, metric sizes .................................................7
6 Suggested initial test current to raise AWG control conductor temperature 100C ......9
7 Suggested initial test current to raise metric control conductor temperature 100C .....9
8 Minimum current cycle periods for AWG control conductors ......................................10
9 Minimum current cycle periods for metric control conductors .....................................11
10 Resistance and temperature measurement intervals ..................................................11
Annexes (Informative)
A Optional Tests to Meet the Requirements of UL 486D................................................18
B Standards which are Applicable to C119.1 by Inference,
but Not Directly Referenced in the Standard ...............................................................19
C Test Loop Diagrams.....................................................................................................20
D Suggested Thermocouple Locations ...........................................................................22
E Guarded Circuit ............................................................................................................24
vi
ANSI C119.1-2006
Foreword (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:
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:
National Electric Energy Testing, Research & Application Center Thomas Champion
vii
ANSI C119.1-2006
The C119.1 Subcommittee on Sealed Underground Connector Systems, which developed the revisions of
this standard, had the following members:
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
viii
AMERICAN NATIONAL STANDARD ANSI C119.1-2006
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.
3 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 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.
1
ANSI C119.1-2006
4 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.
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.
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.
5 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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ANSI C119.1-2006
5.2 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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ANSI C119.1-2006
NOTEThese tables are to ensure mechanical performance for smaller wire sizes where the five percent (5%) minimum is not
adequate for long-term reliability.
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ANSI C119.1-2006
5.5.3 Insulation
The insulation provided as part of the connector system shall show no visible evidence of deterioration
when thermal stability is reached.
5
ANSI C119.1-2006
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
ANSI C119.1-2006
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.
m in. m in.
Over 4/0 Through 750 kcmil Over 2/0 through 500 kcmil 0.6 24 1.2 48
m in.* m in.*
Over 120 mm2 through 380 mm2 Over 70 mm2 through 240 mm2 0.6 24 1.2 48
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ANSI C119.1-2006
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.
8
ANSI C119.1-2006
6 90 8 95
4 125 6 130
2 170 4 180
1 200 2 245
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ANSI C119.1-2006
10
ANSI C119.1-2006
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
11
ANSI C119.1-2006
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:
12
ANSI C119.1-2006
8 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.
13
ANSI C119.1-2006
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.
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ANSI C119.1-2006
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.
15
ANSI C119.1-2006
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).
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ANSI C119.1-2006
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ANSI C119.1-2006
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
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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ANSI C119.1-2006
Annex C
(Informative)
Test Loop Diagrams
d (minimum) d
E1
T1
E2
T2
E3
Tcc 2d Power
Supply
E4
T3
E5
T4
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.
20
ANSI C119.1-2006
30 cm Tc1
(12 in)
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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ANSI C119.1-2006
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.
Figure D.1
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ANSI C119.1-2006
Figure D.2
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ANSI C119.1-2006
Annex E
(Informative)
Guarded Circuit
1 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.
2 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.
3 Circuit Diagrams
Figure E.1
1) A = Ammeter 6) V = Voltage Source
2) I = Current Total; I = ISTRAY + IL 7) VG = Guard Voltage
8) Figure E1, guard should be close to water, (no potential
3) IG = Guard Current
between water and guard), and current measured in water circuit
4) IL = Leakage Current 9) Figure E1, shows VG to water is 0V.
24
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
8) Figure E2, guard should be close to cable core, (no potential
3) IG = Guard Current
between core and guard), and current measured in cable core circuit
4) IL = Leakage Current 9) Figure E2 shows 0V between core and guard
25