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Malaysian Standard: Department of Standards Malaysia
Malaysian Standard: Department of Standards Malaysia
STANDARD
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ICS: 29.060
Descriptors: crimp type cable lugs, XLPE insulated, cooper, single-core power cable applications up to
36 kV, specification for material, marking and dimensions
© Copyright 2005
http://www.dsm.gov.my http://www.sirim.my
E-mail: central@dsm.gov.my
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MS 1838:2005
CONTENTS
Page
1 Scope …………………………………………………………………………………. 1
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3 Definitions ………………………………………………………………………………. 1
4 Requirements…………………………………………………………………………… 2
Tables
3 Overall installed dimensions for crimp type cable lugs for 1 kV & 36 kV ………… 6
Figures
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MS 1838:2005
Committee representation
The Electrotechnical Industry Standards Committee (ISC E) under whose authority this Malaysian Standard was
developed, comprises representatives from the following organisations:
The Technical Committee on Electrical Installation, Protection and Insulation Practice which developed this
Malaysian Standard was managed by The Electrical and Electronics Association of Malaysia (TEEAM) in its capacity
as an authorised Standards-Writing Organisation and consists of representatives from the following organisations:
Suruhanjaya Tenaga
Universiti Malaya
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MS 1838:2005
FOREWORD
This Malaysian Standard is meant to standardise and to prevent the use of inferior and
unsuitable cable lugs in the connection of conductors to electrical equipment, in view of its
widespread use. This Malaysian Standard containing the guidelines for the overall installed
cable lug dimensions is aimed at achieving this goal. In the development of this standard
specification, due consideration was made to the current practices existing in the industry
concerned, and careful consideration of the common usage of crimping tools and dies.
The earlier MS 1540:2002, Specification for the material, marking and dimensions of crimp
type cable lugs for use with copper conductors in low voltage applications was developed for
PVC insulated copper conductors in single & multi core power cables and secondary wiring
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with cross-sections 1.5 mm to 1 000 mm . XLPE insulated and copper conductors have
higher current capacities than their PVC insulated counter-parts. The reason being, the
thermal rating of XLPE insulated cables is 90? C as compared to 70? C for PVC insulated
cables.
XLPE insulated single & multi core cables are economically suitable for power cables and
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therefore the optimum cross-sections have been selected for a range of 25 mm to 630 mm .
Because XLPE is a superior dielectric material, it is best applied as the insulating medium for
higher voltage cables. Therefore, this standard is for the specification for material, marking
and dimensions of heavy duty crimp type cable lugs for use in XLPE insulated and circular
compact copper conductors in single & multi core power cable applications up to 36 kV.
A XLPE insulated and circular compact copper conductor single & multi core cable have an
overall conductor diameter which is smaller than that of a counterpart standard PVC insulated
single & multi core cable. Therefore, cable lugs to MS 1540:2002 do not match-fit XLPE
insulated and circular compact copper conductors; because the lugs barrel inside diameter
are bigger. Without suitable specification as this standard, very often "oversized" standard
cable lugs are crimped onto XLPE cables, resulting in unfit situations. Or, on the other hand
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"undersized" standard lugs used; for example, a 150 mm standard cable lug to MS
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1540:2002 fits a 185 mm XLPE insulated and circular compact copper conductor single &
multi core cable. What a paradox and how unsafe the application; the capacity of the cable
being higher than the cable lug. This standard is therefore developed to avoid dangerous
applications, and thus help to ensure electrical installations are safe.
Compliance with a Malaysian Standard does not of itself confer immunity from legal
obligations.
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MS 1838:2005
HEAVY DUTY CRIMP TYPE CABLE LUGS FOR USE WITH XLPE
INSULATED AND CIRCULAR COMPACT COPPER CONDUCTORS IN
SINGLE AND MULTI CORE POWER CABLE APPLICATIONS UP TO 36 kV
- SPECIFICATION FOR THE MATERIAL, MARKING AND DIMENSIONS
1. Scope
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This Malaysian Standard specifies the construction and the overall installed dimensions of
heavy duty crimp type cable lugs for use with XLPE insulated and circular compact copper
conductors in single & multi core power cable applications up to 36 kV. Dimensions are
provided for the full length, internal diameter of barrel, thickness of barrel, clearance hole for
bolt mounting and chamfer on the lug barrel. This standard specifies the construction
material specification, finishing and markings for cable lugs.
This standard applies to terminal lugs for the circular compact copper conductors of XLPE
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insulated single and multi core power cables with cross-sections 25 mm to 630 mm . This
standard is applicable to cable lugs for both low voltage applications i.e. up to a maximum of
1 kV, and medium voltage applications of greater than 1 kV but up to a maximum of 36 kV.
This standard is applicable to cable lugs with one hole in the palm.
2. Normative references
The following normative references are indispensable for the application of this standard. For
dated references, only the edition cited applies. For undated references, the latest edition of
the normative references (including any amendments) applies.
IEC 61238-2, Compression and mechanical connectors for power cables with copper or
aluminium conductors - Part 2: Terminal lugs for power cables to fit equipment up to and
including 1 kV - Overall dimensions
IEC 60502-2, Power cables with extruded insulation and their accessories for rated voltages
from 1 kV (Um -36 kV) – Part 2: Cables for rated voltages of 6 kV (U m -72 kV) and (U m -36
kV)
3. Definitions
3.1 Connector
Device for connecting a conductor to an equipment terminal or for connecting two or more
conductors to each other.
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MS 1838:2005
3.3 Palm
3.5 Joint
Assembly comprising the connector barrel and that portion of the conductor which has been
brought into immediate contact with it during the crimping process.
3.6 Crimp
4. Requirements
4.1 Construction
The construction for heavy duty cable lugs for low voltage applications and that for medium
voltage applications are as given in Figures 1 and 2 respectively.
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MS 1838:2005
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MS 1838:2005
4.2 Material specification (For both low voltage and medium voltage applications)
4.2.1 The copper for cable lugs shall comply with the specifications given in Table 1.
Description Specification
Material type Copper
Grade of copper Electrolytic Copper (ETP)
a
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4.2.2 The finishing for cable lugs shall comply with the specifications given in Table 2.
Description Specification
Finishing type Electro-tinplating
Purity of tin 99 %
Minimum thickness of tinplating 3 ?m
4.3 Markings (For both low voltage and medium voltage applications)
Cable lugs shall be clearly marked by stamping the conductor size on the palm of the cable
lugs, as shown in Figure 3 & 4.
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MS 1838:2005
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Key:
1 Manufacturer's symbol representation (for the minimum size of 70 mm2 and above)
2 Suitable conductor size
3 Cable lug material and corresponding cable material type (for the minimum size of 70 mm2 and above)
4 "X" - A mark to represent XLPE insulated cable and wire
4.4 Dimensions (For both low voltage and medium voltage applications)
The legend for the various dimensions of this standard is shown in Figure 5 & 6.
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MS 1838:2005
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Table 3. Overall installed dimensions for crimp type cable lugs for 1 kV & 36 kV
Clearance
FL CL
Cable lug size/ hole for
(mm) (mm) ID W t
Wire size bolt
2 Minimum Minimum (mm) (mm) (mm)
(mm ) mounting
Length Length
(mm)
25 36 16.0 6.3 13.5 1.50 8.2 (M8)
35 44 17.0 7.4 16.0 1.70 10.5 (M10)
50 48 20.0 8.6 18.0 1.95 10.5 (M10)
70 53 21.0 10.3 20.5 2.05 12.8 (M12)
95 58 24.0 12.3 25.0 2.60 12.8 (M12)
120 62 28.0 14.2 29.0 2.90 12.8 (M12)
150 70 30.0 15.6 31.5 3.20 16.8 (M16)
185 78 32.0 17.5 37.0 3.25 16.8 (M16)
240 113 43.0 20.0 41.0 4.30 16.8 (M16)
300 117 44.0 22.3 46.5 4.75 16.8 (M16)
400 118 45.0 24.2 50.0 5.10 16.8 (M16)
500 136 52.0 28.0 55.0 5.30 20.0 (M20)
630 143 52.0 32.0 64.0 6.35 20.0 (M20)
NOTES:
2. For ID: 10 mmø and below, allow 0.1 mm tolerance; and above 10 mmø, allow 0.2 mm tolerance.
3. Allow ± 3 % tolerance on t.
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MS 1838:2005
To assist easy entry of cable into the lug, a chamfer of 30? to 45? shall be provided on the
inner edge of the barrel inlet, as shown in Figure 7 & 8.
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Acknowledgements
Ir Rocky Wong Hon Thang (Chairman) The Electrical and Electronics Association of
Malaysia
Puan Khong Choy Tai (Secretary) The Electrical and Electronics Association of
Malaysia
Ir Looi Hip Peu Association of Consulting Engineers Malaysia
Encik Fu Wing Hoong EITA Holdings Sdn Bhd
Ir Chew Shee Fuee G. H. Liew Engineering (1990) Sdn Bhd
Encik Hamdan Arshad Jabatan Bomba dan Penyelamat Malaysia
Ir Chuang Chu Kuen Jabatan Kerja Raya
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