VERIFICATION STATEMENT
FOR AS/NZS 4325.1 (1995) TESTING OF MECHANICAL CONNECTORS
FOR POWER CABLES, HEAT CYCLE TEST
Statement No:
N141ETRU
Valid for products not subject to DNV GL classification requirements.
Particulars of Product
Product Name:
AS/NZS 4325.1 (1995) Testing of Mechanical
Connectors for Power Cables, Heat Cycle Test
Type designation:
Tin-plated aluminium B10 Shear Bolt Lug - 12H400
Application/context:
Shearbolt Lug Cable Connector
ID/Serial/Tag no:
B10-ABXX/12H400
The product is intended for:
STOCK
Requirements are based on:
AS/NZS 4325.1 (1995) + Amdt 1 (1997) Compression and mechanical connectors for power
cables with copper or aluminium conductors, Part 1:
Test methods and requirements
Deviations and limitations, if any, are stated on page 2 onwards.
Particulars of Vendor and Purchaser
Vendor:
TriCab (Australia) Pty Ltd
Vendor reference:
Purchaser:
Purchaser reference:
Issued at Melbourne on 2017-08-15
for DNV GL
This document has been digitally signed and
will therefore not have handwritten signatures
Brown, Adrian
Surveyor
Except for any liability caused by DNV GL's gross negligence or wilful misconduct, DNV GL's maximum cumulative liability arising out of or related
to the use of or reliance on this document shall be limited to USD 300 000.
Form code: 71.07a
Revision: 2017-01
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Page 1 of 2
© DNV GL 2014. DNV GL and the Horizon Graphic are trademarks of DNV GL AS.
Statement No: N141ETRU
Verification extent and result
Verification extent:
At the request of TriCab (Australia) Pty Ltd, the undersigned surveyor was requested to attend the
manufacturer's MV test facility at Port Melbourne for the purpose of witnessing testing of electrical
compression/mechanical connectors.
Cable Type: 300mm2 flexible aluminium cable, LSFLEX R-70 (X-HF-110) insulation and E-Rubber S-20
jacket, 0.6/1kV 110C
Branded Designation: KL-PAXA/1C300 BK Flexible Rubber SDI power cable
Connector Type: TriCab aluminium alloy lug (shear bolt), 32.1mm internal dia. x lug palm cross-sectional
area 840mm2
Branded Designation: B10-ABXX/12H400
Connector Tests: As per AS/NZS 4325.1:1995 + Amdt 1 - 1997, Compression and mechanical
connectors for power cables with copper or aluminium conductors, Part 1: Test methods and
requirements, ie 6.1 (Installation), 6.2.1 (Electrical resistance measurements), 6.3.1 (First heat cycle)
and 6.3.2 (Second heat cycle).
Shear bolt fittings were witnessed assembled on conductors (insulation removed) using an AEG BSS
18C12Z impact drill.
Verification result/comments:
With reference to the above, the cable connectors were arranged in a test circuit for terminal lugs in
accordance to Figure 1 b), bolted palm-to-palm with soldered equalizers. Physical length requirements,
ie d, lr & la/b were as per standard.
The electrical resistance, temperature measurements, first and second heat cycles were conducted and
witnessed, as per attached TriCab Test Report number ACC17013 dated 27th June 2017, in their entirety
by the undersigned surveyor.
Surveyor Supplementary information:
- Please refer to OEM Test Report for further details.
Form code: 71.07a
Revision: 2017-01
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Page 2 of 2
HEAT CYCLE TEST REPORT TO AS/NZS4325.1:1995
TriCab SHEAR BOLT LUGS B10/12H400
Test Report Number:
ACC17013
Supplier:
TriCab
Test Item:
B10-12H400 and KL-PAXA/1C300BK
Test specification:
Testing according to AS/NZS 4325.1 “Compression and
mechanical connectors for power cables with copper and
aluminium conductors Part 1: Test methods and requirements
Test Result:
The shear bolt lugs and cable assembly conform to the Test
Requirement of AS/NZS 4325.1 in determining the parameter
for heat cycling test.
Testing Laboratory:
TriCab (Australia) Pty Ltd
33 Prohasky Street,
Port Melbourne, VIC 3207
Date of Testiing:
27 June 2017
Tested by:
Greg Beziuk (TriCab Engineer)
George Young (TriCab Engineer)
Fernando Agustin (TriCab Technical Manager)
Verified and Witnessed by:
Adrian Brown (DNV-GL)
Results appearing herein relate only to the sample(s) tested. This test report is not permitted to
be reproduced in any form without permission of the test center.
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1. INTRODUCTION
The purpose of this test is to evaluate the performance of TriCab B10-12H400 shear
bolt aluminium lugs when exposed to heat cycle test. Integrity of mechanical joints
between lugs and KL-PAXA/1C300BK flexible aluminium cable was assessed and
evaluated by determining the stability of connection resistance of lug/cable joint and
the relationship of temperature between conductor and lugs.
2. APPLICABLE STANDARD
The test method is based on AS/NZS 4325.1:1995 Standard.
3. TEST DETAIL
3.1. Test Equipment
TriCab Medium Voltage Test Facility is equipped with fully integrated, automatic,
induction Cable Cycle Heating Test System. The system allows to carry-out long term
heating test of copper and aluminium power cables or associated cable connectors
with a total load current of up to 6000A.
The B10-ABXX/12H400 lugs were tested by means of the following equipment:
 Cable Cycle Heating Test System with load current of up to 6000A.
 Pico Technology 8 Channels thermocouple data loggers with associated
software
 Windows PC
 8x K type thermocouples assembly (type 12 608-056 c/w F11K/F40 ATT)
 MILLI-OHMMETER 5894, Tinsley (DC current, 4 terminals sensing ohm-meter)
 Fluke Power Analyser
3.2. Test circuit
The test loop was assembled as per clause 6.1.1 and Figure 1 (b) of AS/NZS
4325.1:1995. The test circuit was designed using the Terminal lugs layout and was
graphically presented on Figure A. All conductors used in the circuit were TriCab KLPAXA/1C300BK. The circuit consisted of:

6 units of B10-ABXX/12H400 that formed 3 pairs of connection (lug1-lug2;
lug3-lug4; lug5-lug6). Every pair of lugs were connected palm to palm as per
Figure 3 (5) of AS/NZS 4325.1:1995.

8 potential equalizers as per Annex 2 of AS/NZS 4325.1:1995.

section of reference conductor with length lr =1.6 m, which was calculated using
the formulae on page 12 of AS/NZS 4325.1:
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≥
≥ 80√
where: A = 300mm2 is cross section area of conductor.

sections of conductors between equalizers and connectors la = 0.26m
(approx.), determined by means of expression in Annex B.1 of AS/NZS
4325.1:1995:
≅ 15√
where: A = 300mm2 is cross section area of conductor.


additional two bimetallic lugs (BL400) not included in test circuit diagram of
AS/NZS 4325.1:1995, marked as lug7 and lug8.
two sections of 1C5002 aluminum conductor terminated on both ends with
bimetal lugs BL630 (section one: lug9, lug10; section two: lug11, lug12) not
included in tests circuit. One end of each section is connected in series to the
end of test circuit using palm to palm connection (lug7 to lug9, lug12 to lug8).
The remaining ends of the additional sections (lug10, lug11) connected palm
direct to palm during the heating test, were used to open the loop when the
resistances were measured.
Figure A: Test Diagram
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4. TEST CIRCUIT ASSEMBLY
4.1. Tested lugs
Lugs were installed on conductor of KL-PAXA/1C300BK cable using AEG BSS
18C12Z impact drill.
4.2. Potential equalizers
Equalizers were constructed using 400mm2 aluminium cable compression links. Hole
with diameter of 10mm was drilled at the centre of cable link for soldering. Cables were
inserted into both link openings with 3mm gap between conductors ends. The gap was
located in the middle of the link. The link was crimped on both ends using IZUMI
EPS60S crimping head and 60T-39.0AFAL die. Solder (ALU-SOL 80/18/2 Solder
Wire) was inserted through drilled hole to solder both ends of crimped conductors and
the link and was heated up using propane torch. The solder filled the gap between
cable ends thus forming a solid connection inside the link and crimping points.
4.3. Lengths of the connectors assembly associated with the measurement
points after jointing
Measured length between equalizer and every individual lug is presented in Table 1.
The distance between lug-conductor joint and lug palm is presented in Table 2. Table
3 consists of length of joint between lugs and conductor.
Table 1. Length of conductor section between lug and equalizer
Equal. - lug
conductor
la1
la2
la3
la4
la5
section
Length
[mm]
300
304
308
300
296
la6
287
Table 2. Length of distance between end of lug barrel and conductor-lug joint
Joint - palm
section
lb1
lb2
lb3
lb4
lb5
lb6
Length
[mm]
28
28
28
28
28
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Page 4 of 9
Table 3. Length of joint between lug and conductor
Joint
section
lj1
lj2
lj3
lj4
Length
[mm]
87
87
87
87
LJ5
lJ6
87
87
The length of reference cable that was measured after assembly as a distance
between the middles of equalizers is equal to lr.= 1520 mm.
4.4. Additional pair of bimetal lugs
Both ends of test circuit was terminated using bimetal lugs BL400 crimped on the
conductor by means of IZUMI EPS60S crimping head and 60T-39.0AFAL die.
4.5. Additional pair of 500mm2 cable sections terminated with bimetal lugs
Two additional sections of KL-PAXA/1C500BK aluminium cable with 1980mm and
1855mm long, were terminated on both ends with BL630 lugs using IZUMI EPS60S
crimping head and 60T-43.0AFAL die. This sections are connected in series with test
circuit and joint between them was used to open the test loop when resistances in the
circuit were measured.
4.6. Thermocouple for measuring the reference conductor temperature
The reference conductor temperatures were measured by thermocouple inserted into
the hole at the point in the middle length of the reference cable.
4.7. Thermocouple for measuring the lug temperature
The temperatures of lugs were measured by thermocouple secured to the surface of
lug by means of nylon cables ties.
5. TEST PROCEDURE
5.1. Measurement of Resistance
After installation of all components of testing loop with pair lug10-lug11 disconnected,
resistance between potential points was measured as required by AS/NZS
4325.1:1995 (Annex B.1, Figure 3 case 2). The measured resistance together with
values of associated temperatures (Annex B.2, Figure 3 case 2) are presented in Table
4.
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Table 4. The results of measurements resistances before first heat cycle
Measurement Rpp1a-pp1b Rpp2a-pp2b Rpp3a-pp3b Rpp4a-pp4b Rpp5a-pp5b Rpp6a-pp6b
point
Rref
Temperature
 [0C]
R [Ω]
15.65
15.72
15.68
15.50
15.47
15.52
15.67
33.1
34.5
33.5
33.7
33.7
32.7
132.1
After measurement of resistances, lug10 and 11 were connected to close the test
circuit.
5.2. First heat cycle
The first heat cycle is to determine the value of equilibrium current (IN) when conductor
temperature reached 140oC. The value will be used in subsequent cycles and the
result is presented in Table 5.
Table 5. Results determined during the first heat cycle
Conductor temperature
IN
[A]
R [0C]
139.59
980
Note: Equilibrium was achieved after 15 minutes with conductor temperature changed from139.360C to
139.590C and median lug (no 3) temperature changed from 94.710C to 95.780C
5.3. Second heat cycle
The scope of second heat cycle is to determine the heating and cooling times, t1 and
t2 respectively, based on parameters measured during the first heat cycle. The results
of the test are presented in Table 6. and the graph of temperature vs time of cycle 1
and 2 is presented on Figure B.
Table 6. Heating and cooling time and total period of heat cycle
Heating time
Cooling time
Total heat cycle time
t1 [min]
t2 [min]
t1 + t2 [min]
110
53
163
Note: The heating time includes applying for initial 15 minutes of heating cycle the accelerating current of
1.4kA
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FIGURE B. Logged of temperature vs time taken from heat cycle 1 and 2
6. RESULTS
In order to asses the influence of heating-cooling cycles on lug-conductor joints
parameters, based on AS/NZS 4325.1:1995 (Annex E.2), the resistances presented in
Tables 4 should be recalculated in reference to temperature of 200 C using equations:
-
for measuring points spanning the connector
(
) =
1 + (Θ − 20)
where:  = 0.004 [1/K] is resistance temperature coefficient for copper and  is lug
temperature; X is a number of connector.
-
for reference cable
(
) =
1+
Θ
− 20
where ref is reference cable temperature.
The results of the calculations are shown in Table 7.
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Table 7. Values of resistances referred to 200 C
Measurement Rpp1aRpp2aRpp3aRpp4app1b(20C)
pp2b(20C)
pp3b(20C)
pp4b(20C)
point
Resistances
referred
to
33.69
35.10
34.09
34.32
200C
Rj [Ω]
Rpp5a-
Rpp6a-
pp5b(20C)
pp6b(20C)
34.32
33.30
Rref(20C)
134.43
Subsequently, joint resistance for each connector was determined using data
presented in Tables 1,2,7 and the length of reference conductor, by means of
expression (Annex E.2 of AS/NZS 4325.1:1995):
=
+
)−
(
(
)
where: X is number of tested lug.
The joints resistances are presented in Table 8.
Table 8. Resistances of lug-conductor joints
Lug no
Rj1
Rj2
Rj3
4.68
R [Ω]
5.74
4.37
Rj4
Rj5
Rj6
5.31
5.67
5.44
Then, for every individual lug was determined connector resistance factor ‘k’. The
factor was calculated using results from Tables 3 and 7, the length of reference
conductor and equation (Annex E.2 of AS/NZS 4325.1:1995):
=
(
)
where: X is number of the connector
In Table 9 are included values of resistance factor ‘k’ for each connector.
Table 9. Connectors resistance factor
k1
k2
k3
k4
k5
k6
0.61
0.74
0.71
0.75
0.57
0.69
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7. INITIAL SCATTER 
The initial scatter provides information as to how the design of a contact system will
behave on a certain conductor immediately after installation before any ageing effect
starts. It helps the identification of a specific connector type ‘family’. The initial scatter
can be determined using equation (Annex E.3 of AS/NZS 4325.1:1995):
=
1
√
where:
- N is a number of connectors;
-
is mean value of connectors resistance factor calculated by means of expression:
=
1
where X is a connector number;
- s0 is corrected sample standard deviation calculated with equation:
=
1
−1
(
−
)
- ts = 4.032 is the Student coefficient for 99% two-sided confidence level and five
degrees of freedom.
For N = 6 and results presented in Table 9, the above parameters have following
values:
= 0.6759, = 0.072; = 0.1753.
8. CONCLUSION
The set-up of specimens and the method of measuring the resistances and
temperature and the data obtained from verification are consistent to test method
stipulated in AS/NZS4325:1. The tested shear bolt lugs satisfied the initial
requirements described in the AS/NZS4325:1. It is clearly indicated by value of
calculated initial resistance scatter = 0.1753 which lies within the range accepted by
the standard ( ≤ 0.3).
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