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Test Date 31 January 2013

Test Reference Method for mechanical test in accordance with Standard AS1154‐2009, Part 1
Section 3.3.1. Holding Strength Test For Full tension, and for Heat Cycle Test
in accordance with IEC 61284, class A, for 500 cycles, for 90° C conductor
maximum continuous current rating

Description of Test The type test was divided into 2 parts.

1. Mechanical Strength Test
2. Heat Cycle Test

Test Quantity 1. 4 Clevis Compression Dead End 340/30 ACSR Part No. ID0630‐000 as
shown on drawing number DI3590/1
2. 4 Compression Midspan Joint 340/30 ACSR Part No. ID0777‐000 as shown
on drawing number DI3731/1

Objective of Test The purpose of the Mechanical Strength & Heat Cycle Test is to perform
type tests on Fittings for Overhead Lines, The Operative standard is AS
1154.1‐2009 clause 3.3.1 and IEC 61284. Second edition. The particular tests
performed are the heat cycle tests for class A

Methods of Test A. MECHANICAL STRENGTH TYPE TESTS

A. 1. Holding strength test for full tension fittings

A.1.1 Test assembly

The test shall be performed according to AS 1154.1‐2009 clause 3.3.1 the

free length of the conductor between the fitting under the test and any other
clamp or fitting in the test assembly shall be not less than 100 times the
overall diameter of the conductor.

A.1.2 Procedure

A tensile force of approximately 50% CBL (conductor breaking load)

340/30 ACSR “45.55 kN” shall be applied and the conductor shall be marked
such a way that movement relative to the fitting can be detected. Without
any subsequent adjustment to the fitting, the force shall be increased to 90%
CBL (conductor breaking load) 340/30 ACSR “82 kN” and maintained for 1
minute. The force shall then be increased steadily until failure occurs. The
load and nature of the failure shall be recorded.
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A.1.3 Acceptance criteria :

During the 1 minute period in which the tensile force is held at 90% of the
nominated breaking load of the conductor, there shall be no movement of the
conductor relative to the joint due to slip nor any failure of the fittings.

Test Result: Results refer to the NATATT008 PLP INDO Comp. Fittings

B. Heat Cycle Test

1. A Test Arrangement

1.1. Test conditions

The test shall be carried out in reasonably draught‐free conditions at an
ambient temperature between 15ᴼC and 30ᴼC. The test assembly shall be
erected so that the distance between joints, or any other connections
introduced to facilitate testing, shall be sufficient to ensure negligible thermal
interference. The assembly shall be supported in such a way that air may
freely circulate around the assembly to provide cooling by natural convection.
If accelerated cooling is employed this shall affect the whole assembly
uniformly.
The tests shall be carried out employing new conductors, and a
mechanical tension not exceeding 20% of the rated tensile strength of the
main conductor may be applied to the assembly of tension joints.

1.2. Reference conductor

For the purpose of resistance and temperature measurements, the
assembly shall contain a length of unjointed conductor which shall be used as
the reference for resistance and temperature measurements. If a joints is
such that two sizes of conductor are being connected into the assembly, the
smaller of the two shall be used as the reference conductor. The length of the
reference conductor shall be no less than 100 times its diameter, up to a
maximum of 4 m long.

1.3. Potential points

Potential points for resistance measurements shall be installed on the
conductor at a distance of 25mm from the ends of all test joints.
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Typical Potential Points

1.4. Measurements

1.4.1. Resistance measurements

The resistance of each test joint and reference conductor shall be
measured between the potential points installed in accordance with clause
potential points.

In carrying out resistance measurements, the temperature of reference

conductor and test joints shall be read and the resistance value obtained shall
be related to 20ᴼC by means of the following formula:

Where

Rθ = is the measured resistance

θ = is the temperature (in degree celcius) of the joint or the
reference conductor when it is measured
α₂₀ = is the thermal coefficient of resistance

This coefficient can be taken equal to :

α₂₀ = 4 x 10⁻ᶾ/ᴼC for cooper, alluminium and ACSR
α₂₀ = 3.6 x 10⁻ᶾ/ᴼC for alluminium alloy

The resistance measurements shall be made with direct current having a

magnitude not higher that 10% of the a.c test current. The temporary current
connections used for resistance measurements shall be at a distance of not
less than 50 times the diameter of the conductor from the joint and shall be
made so that effective contact is made with all those strands of the conductor
which would be taken into account in calculating its equivalent resistance.

Instruments used for resistance measurement shall be accurated to within

1% or 0.5 μΩ, whichever is the greater when the instrument is calibrated
against a certified standard resistance bar.
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1.4.2. Temperature measurements

The temperatures of the joints and reference conductors, including
ambient, shall be measured by thermocouples or by other suitable means
with an accuracy of 2ᴼC or better.

The joint temperature recorded shall be that of the hottest part of its
surface. The thermocouple may either be inserted in a small hole drilled into
the joint or secured to the outside surface.
On the reference conductor the thermocouple shall be positioned at the
mid‐point and securely located, either In a small hole drilled into a solid
conductor or by sliding it under the strands of the outer layer of a stranded
conductor.

The device to measure the ambient temperature throughout the test shall
be placed so as not to be influenced by the heat dissipation of the test circuit.

2. Heat cycle test procedure

2.1. General
The heat cycle test shall consist of N electrical load cycles. The number N
of cycles shall be chosen from table 3. Short‐time overcurrent impulses shall
be applied to class B joint in accordance with 13.3.1 and also to class A joints
when N cycles =100.

Each cycle includes a heating period where the test assembly is loaded by
the test current, followed by a subsequent cooling period with the current
switched off.
The heat cycle test shall be carried out employing an alternating current
Table – Conditions For Heat Cycle Test

.
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2.2. Joints of class A

2.2.1. Test procedure

The joints of class A shall be tested by the electrical heat cycle (N cycles)
method described below :

A. The test shall be carried out on the joints prepared in accordance to

the supplier's instructions on conductors of the size and type with
which they are to be employed without any further preparation. After
the four joints have been placed in the test assembly, but prior to
heat cycling, the resistane across each joint and the resistance of the
reference conductor shall be measured as specified in Resistance
Measurement taking into account the length of the joint, the
resistance of an equivalent length of the reference conductor shall
then be calculated

B. A test current shall then be passed through the assembly. The value
and duration of the test current shall be such as to raise the reference
conductor temperature to the value of (see table‐conditions
for heat cycle test) above ambient and maintain this temperature for
30 min. The use of an initial current of value not greater than 150% of
the test current, to provide accelerated heating so as to reduce the
time to raise the conductor to above ambient, is permitted.

C. At the end of the heating period the current shall be interrupted and
the conductor allowed to cool to within 5ᴼC above ambient. Forced
cooling to reduce the time cycle is permitted.

D. This sequence of operation shall be repeated so that 0.1 N cycles

(±0.02 N cycles) of heating and cooling are applied.

E. On one occasion during the last five cycles of 0.1 N cycles (±0.02 N
cycles) the conductor temperature and temperature of each joint
shall be measured during the last 15 min of the 30 min period.

F. The assembly shall then be allowed to cool to ambient and the

resistance of each joint measured and recorded.

G. Heat cycling shall then be continued with temperature and resistance

measurement at the end of each 0.1 N cycles until 0.5 N cycles have
been completed.
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H. A further 0.5 N cycles shall then follow with resistance measurements

taken every 0.05 N cycles (±0.01 N cycles) and temperature
measurement every 0.1 N cycles (±0.02 N cycles)
The joint shall not be tightened or adjusted during the test.

2.2.2. Acceptance criteria (class A joints) :

Each joint shall meet the following criteria.

A. The initial resistance of the joint shall not differ by more than 30%
from the mean of the initial resistance of each of the four joints
assembled for test.

B. The temperature of the surface of the joint, measured every 0.1 N

cycles when the test current is flowing, shall not exceed that of the
reference conductor.

C. The electrical resistance of the joint, measured at the end of every 0.1
N cycles at ambient temperature , shall not exceed 75 % of the
measured resistance of the equivalent length of the reference
conductor.

D. The average resistance of the joint over the last 0.5 N cycles shall not
exceed the initial resistance of the joint by more than 50%.

E. A graph of resistance against number of cycles shall demonstrate with

a reasonable probability that the rise in resistance over the last 0.5 N
cycles is not more than 15% of the average resistance over the same
period.

Test Result: Results are presented in Appendix A

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Statement of 1. The results indicate that the design of the items tested complies with
Compliance the requirement of the Australian Standard AS1154‐2009, Part 1, Section 3.3.1.
Signature Holding Strength Test For Full tension.

2. These joints comply with the requirements of the heat cycles tests of IEC 61284,
Second edition, 1997‐09, for class A connector.

Reported by : Checked by :

Perdananto Ari Nugroho Leksono Hartanto

Development Engineer Assistant Engineering Manager

Approved by :

Sentot Aliwinoto
QA & Engineering Manager
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Appendix A

Summary Of Results 1
1. FITTING DETAILS

GROUP ITEMS DESCRIPTION PART NO DRAWINGS

A CDE 1‐4 Compression Deadends ID0630‐000 DI3590
B CMJ 1‐4 Compression Midspanjoint ID0777‐000 DI3731

2. CONDUCTOR SPECIFICATION

NAME : 340/30 TYPE : ACSR

MANUFACTURE :‐ STRANDING : 48/3.00 Al & 7/2.33 Fe
NOMINAL CSA
: 25
OD (ALUMINIUM) : 339.3 mm²
RTS : 91.2 KN SMFL (95% RTS) : 86.64 KN
MEASURED DC
: 0.085 ohm/km (20 ᴼC)
DC RESIST RESIST : 0.075 ohm/km (20 ᴼC)

3. TEST RESULT
Results of conformance tests for connectors, to clause 13 " Heat Cycle Tests", of IES 61284, Second
edition 1997‐09, "Overhead Lines Requirements and Tests For Fittings "
GROUP A GROUP B
ACCEPTANCE CRITERIA COMPRESSION COMPRESSION MIDSPAN
DEADEND JOINT
LIMIT
DIFFERENCE BETWEEN EACH JOINT RESISTANCE
PASS PASS
AND AVERAGE RESISTANCE JOINTS CYCLE 0 30.0%

FITTING SURFACE TEMPERATURE SHALL NOT EXCEED REFERENCE

PASS PASS
COND. TEMPERATURE AT ANY TIME

LIMIT
MAXIMUM RESISTANCE FACTOR AT EVERY 50
PASS PASS
CYCLES 75.0%

INCREASE OF AVERAGE JOINT RESISTANCE LIMIT

OVER LAST 250 CYCLES W R T INITIAL PASS PASS
50.0%
RESISTANCE
LIMIT
CHANGE IN RESISTANCE OF FITTING OVER LAST
PASS PASS
250 CYCLES 15.0%
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Summary Of Results 2

ANALYSIS‐ALL JOINTS

1 2 3 4
INITIAL DEVIATION OF MAXIMUM INCREASE OF AVERAGE
FITTING SURFACE MAXIMUM
ACCEPTANCE RESISTANCE JOINT RESISTANCE OVER LAST
TEMPERATURE RESISTANCE FACTOR
CRITERIA FROM AVERAGE 250 CYCLES w.r.t
AT EVERY 50 CYCLES
RESISTANCE AT CYCLE 0 JOINT °C REF °C INTITAL RESISTANCE

LIMIT 30.0% REF °C 75.0% 50.0%

CDE1 1.7% 82.8 130 44.8% 0.4%

COMPRESSION
DEAD END
GROUP A

CDE2 9.9% 84.9 130 39.6% 5.2%

CDE3 4.1% 85.3 130 50.1% 4.2%

CDE4 4.2% 83.4 130 45.5% 3.3%

PASS PASS PASS PASS

MIDSPAN JOINTS

CMJ1 6.1% 86.6 130 34.4% 10.4%

COMPRESSION
GROUP B

CMJ2 1.7% 84.0 130 29.4% 5.7%

CMJ3 2.0% 81.1 130 30.8% 9.4%

CMJ4 6.4% 76.1 130 27.6% 5.0%

PASS PASS PASS PASS

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5. CHANGE IN RESISTANCE OF LAST 0.5 N READINGS

LIMIT ≤ 15%

GROUP A GROUP B

CDE 1 CDE 2 CDE 3 CDE 4 CMJ 1 CMJ 2 CMJ 3 CMJ 4

Mean
R = 24.594 20.569 26.131 24.294 17.885 17.418 17.381 16.713
Resistance
B may
be
Slope B positive 0.032 ‐0.086 0.005 ‐0.017 0.036 ‐0.061 ‐0.020 ‐0.019
or
negative
Change of
M M≤0.15 0.013 ‐0.042 0.002 ‐0.007 0.020 ‐0.035 ‐0.011 ‐0.012
Resistance
A1 ‐0.037 0.401 ‐0.070 0.301 0.035 0.026 0.076 0.251

A2 0.300 0.472 ‐0.058 ‐0.342 0.171 0.236 0.180 0.020

A3 ‐0.661 ‐0.659 0.074 ‐0.317 0.424 0.123 0.120 ‐0.130

Extend change A4 0.471 ‐0.432 ‐0.029 0.353 ‐0.391 0.068 ‐0.070 ‐0.196
of resistance
A5 ‐0.053 0.123 0.537 0.221 ‐0.119 ‐0.159 0.407 ‐0.103
calculation to
take account A6 ‐0.189 0.034 ‐0.296 ‐0.179 ‐0.481 ‐0.068 ‐0.400 ‐0.039
of the scatter
of resistance A7 0.109 ‐0.096 ‐0.239 ‐0.166 ‐0.081 ‐0.588 ‐1.054 0.076
readings
A8 0.221 ‐0.124 ‐0.173 0.004 ‐0.427 0.234 0.665 0.394
around the
line of best fit A9 ‐0.026 0.001 0.288 0.128 0.821 ‐0.597 ‐0.772 ‐0.348

A10 ‐0.123 ‐0.119 ‐0.007 0.095 0.544 0.289 0.473 ‐0.256

A11 ‐0.012 0.398 ‐0.026 ‐0.099 ‐0.495 0.435 0.376 0.331

S 0.026 0.037 0.020 0.022 0.055 0.042 0.068 0.032

D≤
0.039 ‐0.005 0.022 0.015 0.075 0.007 0.056 0.020
Acceptance 0.15
D
criteria D≤
3.9% ‐0.5% 2.2% 1.5% 7.5% 0.7% 5.6% 2.0%
15%

PASS PASS PASS PASS PASS PASS PASS PASS

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CONSTANT & MEASUREMENT DATA

RIG DIMENSIONS

REFERENCE CONDUCTOR MR
2520
"mm"
Length Potential Points
FITTING CONSTANT
joint "mm" "mm"
GROUP A COMPRESSION

CDE1 670 25 REFERENCE TEMP RISE : 100ᴼC

DEADEND

CDE2 640 25 No. of HEAT CYCLES : 500

CDE3 650 25 CLASS of TESTS : A

Potential Points
CDE4 660 25
"mm"
GROUP B COMPRESSION

CMJ1 665 25 25
MIDSPAN JOINTS

CMJ2 665 25 25

CMJ3 665 25 25

CMJ4 665 25 25
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RESULTS ‐ REFERENCE CONDUCTOR

COND. TEMP. CORRECTED

CURRENT AMBIENT TEMP. COND. TEMP. RESISTANCE
CYCLE HOLDING RESISTANCE
NO DATE HEATING TIME COOLING TIME COOLING TIME MEASURED
No. "N" TIME (15'‐30') @20 ᴼC
A (Ampere) ᴼC ᴼC ᴼC micro‐ohms micro‐ohms
1 0 2‐Jan‐13 74.8 30.7 26.5 130 194.4 189.5
2 42 4‐Jan‐13 74.9 27.3 24.2 130 192.8 189.6
3 98 7‐Jan‐13 74.8 28.3 24 130 196.6 193.5
4 144 9‐Jan‐13 74.8 28 25.4 130 191.2 187.2
5 199 12‐Jan‐13 75 31 29.8 130 194.6 187.3
6 242 14‐Jan‐13 74.6 31 26.3 130 191.1 186.4
7 276 16‐Jan‐13 74.7 26 27.9 130 191.4 185.5
8 301 17‐Jan‐13 74.8 30.8 29.6 130 194.4 187.2
9 321 18‐Jan‐13 74.5 28.5 26.6 130 194.5 189.5
10 346 21‐Jan‐13 74.8 31 26.6 130 193 188.0
11 380 23‐Jan‐13 74.6 28.3 27.9 130 191.4 185.5
12 401 24‐Jan‐13 74.8 28.7 27.6 130 192.2 186.5
13 427 25‐Jan‐13 74.8 28.8 26.9 130 192.3 187.1
14 446 26‐Jan‐13 74.8 31.5 28.2 130 192.4 186.3
15 474 29‐Jan‐13 74.6 31 28.9 130 191.4 184.8
16 500 31‐Jan‐13 74.6 30.8 26 130 191.6 187.1

AVERAGE RESISTANCE 187.6 micro‐

OVERALL 1.1%
STANDARD DEVIATION OF AVERAGE RESISTANCE
LAST 250 0.7%

RESISTANCE @20ᴼC
200.0
195.0
190.0
185.0
180.0
175.0
170.0
0 42 98 144 199 242 276 301 321 346 380 401 427 446 474 500
CYCLE
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GRAPHS ‐ GROUP COMPRESSION DEAD END

RESISTANCE FACTOR CDE 1

R 0.80
E
S 0.60
I
0.40
S
T
0.20
A
N
0.00
C
E 0 42 98 144 199 242 276 301 321 346 380 401 427 446 474 500
CYCLE

RESISTANCE FACTOR CDE 2

0.80
R
E 0.60
S
I 0.40
S
T 0.20
A
N 0.00
C 0 42 98 144 199 242 276 301 321 346 380 401 427 446 474 500
E CYCLE

RESISTANCE FACTOR CDE 3

0.80
R
E
0.60
S
I
0.40
S
T 0.20
A
N 0.00
C
E 0 42 98 144 199 242 276 301 321 346 380 401 427 446 474 500
CYCLE

RESISTANCE FACTOR CDE 4

0.80
R
E 0.60
S
I 0.40
S
T 0.20
A
N 0.00
C 0 42 98 144 199 242 276 301 321 346 380 401 427 446 474 500
E
CYCLE
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GRAPHS ‐ GROUP COMPRESSION MIDSPAN JOINT

RESISTANCE FACTOR CMJ 1

0.60
R
E 0.45
S
I 0.30
S
T 0.15
A
N 0.00
C 0 42 98 144 199 242 276 301 321 346 380 401 427 446 474 500
E CYCLE

RESISTANCE FACTOR CMJ 2

0.60
R
E 0.45
S
I 0.30
S
T 0.15
A
N 0.00
C 0 42 98 144 199 242 276 301 321 346 380 401 427 446 474 500
E CYCLE

RESISTANCE FACTOR CMJ 3

0.60
R
E 0.45
S
I 0.30
S
T 0.15
A
N 0.00
C 0 42 98 144 199 242 276 301 321 346 380 401 427 446 474 500
E
CYCLE

RESISTANCE FACTOR CMJ 4

0.60
R
E 0.45
S
I 0.30
S
T 0.15
A
N 0.00
C 0 42 98 144 199 242 276 301 321 346 380 401 427 446 474 500
E CYCLE
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FINAL TEMPERATURE 1
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FINAL TEMPERATURE 2
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Appendix B ‐ Drawing

‐ Compression Dead End For Conductor 340/30 ACSR

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‐ Compression Midspan Joint For Conductor 340/30 ACSR

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‐ Heat Cycle Test Rig

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Appendix C ‐ Photos

- Test setup
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- Control Panel
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- Compression Dead End Aseembly

- Compression Midspan Joint Assembly