ECE1

TECHNICAL SPECIFICATION FOR

ELECTROFUSION CONTROL BOXES

AUGUST 1992
J236 (Rev 11/02)
.
 ECE1

CONTENTS

Page

FOREWORD iii

BRIEF HISTORY iv

1. SCOPE 1

2. REFERENCES 1

3. DEFINITIONS 1

4. CONSTRUCTION REQUIREMENTS 1

5. OPERATING REQUIREMENTS 2

6. RESPONSE TO SELECTION OF FUSION TIMES 4

6.1 Mode selection switch 4

6.2 Manual selection 4

6.3 Manual selection with automatic verification 4

6.4 Automatic selection 4

7. DOCUMENTATION 4

8. TEST REQUIREMENTS 4

8.1 General 4

8.2 Free fall test 5

8.3 Bump test 5

8.4 Vibration test 5

8.5 Insulation test 5

9. OUTPUT CABLE 6

9.1 General 6

9.2 Manual selection 6

9.3 Automatic selection/verification 7

10. TESTING 7

10.1 General 7

10.2 Type approval testing 7

10.3 Batch acceptance testing 8

11. VARIANTS 8

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Page

TABLES

1 Operating parameters 9

2 Duty cycle 9

3 Trip settings for output voltage 9

4 Schedule of type approval tests 10

4a) Control box 10

4b) Output cable 10

5 Connector types 11

5a) Connectors to BS 9522 FOO32 11

5b) Connectors to VG 95234 Teil 3 11

Test conditions at 23 C
0
6 11

7 Self-heating test conditions 11

8 Schedule of batch acceptance tests 12

8a) Control box 12

8b) Output cable 12

9 Test conditions 12

APPENDICES

A DATA LOGGING AND RETRIEVAL (OPTIONAL) 13

B SPECIFIC REQUIREMENTS AND TESTING FOR COMBINED ELECTROFUSION

CONTROL AND POWER GENERATION SYSTEMS 14

C LIST OF REFERENCES 17

D ENVIRONMENTAL TESTING OF ELECTROFUSION CONNECTOR 19

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FOREWORD

Comments and queries regarding the Technical content of this engineering document should be directed to:

Engineering Policy
Transco
Brick Kiln Street
Off Coventry Road
Hinckley
Leicestershire
LE10 0NA

Further copies of this engineering document can be obtained from Dataform Print Management using the
print requisition form G004 quoting the Form Number of this Transco engineering document (not the
designation) and your cost code.

Transco documents are revised, when necessary, by the issue of new editions. Users should ensure that they
are in possession of the latest edition by referring to the Transco Register of Engineering Documents
available on TransNet.

Compliance with this engineering document does not confer immunity from prosecution for breach of
statutory or other legal obligations.

Contractors and other users external to Transco should direct their requests for further copies of Transco
engineering documents to the department or group responsible for the initial issue of their contract
documentation.

DISCLAIMER

This engineering document is provided for use by Transco and such of its contractors as are obliged by the
terms and conditions of their contracts to comply with this engineering document. Where this engineering
document is used by any other party it is the responsibility of that party to ensure that the engineering
document is correctly applied.

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BRIEF HISTORY

First published as GBE/ECE1 August 1992

Editorial update to reflect demerger November 2000 June 2001

Editorial update to reflect merger October 2002 November 2002

© Transco plc.

This engineering document is copyright and must not be reproduced in whole or in part by any means without the
approval in writing of Transco plc.

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 ECE1

TECHNICAL SPECIFICATION FOR

ELECTROFUSION CONTROL BOXES

1. SCOPE
1.1 This Transco Technical Specification* specifies the construction, operating requirements and
performance testing of electrofusion control boxes and associated cables, for use with fittings produced in
accordance with BS 7336.
* Hereinafter referred to as ‘this specification’.

This specification covers both manual selection and automatic selection of fusion times, and automatic
verification of manual selection.

1.2 The normal operating ambient temperature of the control box will be in the range − 50 C to
40 0 C . However, storage temperatures as low as − 10 0 C may be encountered.

1.3 The requirements for data storage and retrieval are specified in Appendix A.

1.4 This specification may be used for the design of combined electrofusion control and power
generation systems with the specific requirements specified in Appendix B.

2. REFERENCES
This specification makes reference to the documents listed in Appendix C.

3. DEFINITIONS
For the purposes of this specification the following definitions shall apply:

Conformal coating: an impervious coating which conforms to the irregular surface of components
mounted on a printed circuit board (PCB).

Contractor: the person, firm or company with whom Transco enters into a contract to which this
specification applies, including the Contractor's personal representatives, successors and permitted assigns.

4. CONSTRUCTION REQUIREMENTS
4.1 The control box, frame (if supplied) and associated input cable shall be not heavier than 30 kg.
The design shall allow for the control box to be carried by one person.

The control box shall be designed and constructed in such a manner as to afford protection against electric
shock, in accordance with BS 2754.

4.2 The control box enclosure shall be in accordance with BS 5420 IP 54 with the socket-outlet
exposed. The structural integrity of the control box shall be established by the tests specified in clause 8.

All PCBs shall be conformally coated to protect against the effects of condensation.

4.3 The control box should be designed to allow ease of calibration and maintenance.

The Contractor shall supply an instruction manual in accordance with BS 4884.

Maintenance shall be in accordance with EL3.

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4.4 The input cable shall be permanently attached to the control box, and its nominal length shall be
10 m. The maximum voltage drop shall be 2.75 V ac rms (lead and return) when measured at maximum
input current (see 5.1).

The input cable shall be flexible 3-core with overall screening. The input cable/insulation shall be PVC to
BS 6746, Type TI1 with a PVC cable sheath to Type TM1 and flexible conductors to BS 6360.

The earth core and screening shall be bonded to the transformer interwinding screen and any exposed metal
parts. The input cable supply source end shall terminate at a 3-pin, 110 V, 32 A plug to BS 4343. The cable
screen shall be connected along with the earth core of the cable into the earth pin of the plug.

NOTE - BS 4343 plug and socket ratings are based upon breaking capacity. For
electrofusion duty cycles, higher current levels can be tolerated by this plug design.

A facility for input cable winding, storage and protection during handling shall be available on the control
box. Trailing flexible cables shall be protected against stresses encountered during normal service.

4.5 The output cable socket-outlet shall be fixed to the control box panel.

4.6 The control box shall be permanently marked with:

a) the maker's name;

b) serial number;
c) input voltage;
d) output voltage;
e) input current;
f) output current;
g) degree of protection;
h) specification number (i.e. ECE1).

4.7 The START push button switch shall be electromechanically operated. It shall be coloured green.

4.8 The control box shall be fitted with a red STOP pushbutton, which completely interrupts the
output by operating directly on the main contactor coil. The STOP pushbutton switch shall be
electromechanically operated.

4.9 All transformers shall be safety isolating transformers to BS 3535.

4.10 The output current shall be continuously monitored for the duration of the fusion cycle. Any
increase in current greater than 10% during any 4 s period should cause the control box to switch off and
indicate a fault condition.

5. OPERATING REQUIREMENTS
5.1 The control box shall be designed to operate from a nominal 110 V, 50 Hz sinusoidal supply with
either one pole earthed or with the mid-point earthed.

The control box should be suitable for use with all generators used by Transco or its contractors. These
generators may be different to the current ECE3 specification due to their age.

NOTE - Typically, a transportable 110 V generator output will be 97 V to 150 V ac

rms having a sinusoidal waveform with not more than 25% distortion and within the
frequency limits of not less than 40 Hz and not greater than 70 Hz. The sub-transient
reactance of a generator may be as high as 60 mH. The generator's minimum rate of
rise of current may be assumed to be 2000 A/s.

Residual current circuit breakers (RCCBs) may be fitted to the input service supply and shall not be derated
by any component or circuitry used in the operation of the control box.
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Overload protection shall be fitted to the input side of the control unit in an accessible position.

When the control box is delivering maximum output at minimum input voltage (97 V) from the generator,
the input current shall not exceed the value given in Table 1.

5.2 The output from the control box shall be stabilized to give the output voltage given in Table 1
when delivering the corresponding range of output currents. The stable voltage shall be achieved within 1 s
from start of applied voltage.

The control box circuitry shall use the voltage sensed by separate connectors, other than the power
connectors, onto the fitting terminals to control the voltage to the electrofusion fitting. Where the output
voltage limits and the output voltage control circuitry are derived from the same voltage reference, an
independent means of checking this reference shall be provided.

5.3 At an ambient temperature of 40 0 C , the control box shall be capable of undergoing the duty
cycle given in Table 2.

5.4 The fusion cycle times shall be controlled to an accuracy of ± 0.5% for any setting over an
ambient temperature range of − 10 0 C to 40 0 C . The timing system accuracy shall be maintained within
these limits without adjustment for a period of at least 12 months.

NOTE - The frequency variation of the generators may be between the limits of not
less than 40 Hz to not greater than 70 Hz.

5.5 The control box shall check the continuity of the fusion coil and the integrity of the output circuit
before the main power is allowed to be switched on to the fitting. The continuity circuit shall be powered by
not more than 12 V. The control box shall not operate when attached to resistances above 200 Ω . The
control box circuit shall measure continuity across voltage sense pins on the output socket. The continuity
of this circuit shall be continously monitored during the fusion cycle. Any break in the circuit shall switch
off the control box and indicate a fault condition.

5.6 The control box shall display the following information:

a) INPUT VOLTAGE 'ON'.

b) INITIAL FUSION CYCLE TIME - DECREMENTING IN SECONDS TO ZERO.
c) FUSION COMPLETE.
d) FAULT - see 5.7.

5.7 Each of the following faults shall be uniquely identified when it occurs:

a) Output voltage outside the tolerance band: these trips shall be set as in Table 3 and shall
operate in less than 6 s.
b) Break in circuit.
c) Fusion time not on preferred list of times.
d) Incorrect fusion time selected - this will display when the auto identification system does not
confirm the fusion time manually selected by the operator.
e) Fitting not recognized - this will display when the automatic identification system is unable
to recognize the attached fitting.
f) Interrupted fusion cycle.
g) Input voltage in excess of 150 V.
h) Partial short circuit of fusion coil.

The output circuit shall be switched off automatically if a fault occurs.

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5.8 All displays shall be clearly visible both in bright sunlight and in subdued lighting conditions.

6. RESPONSE TO SELECTION OF FUSION TIMES

6.1 Mode selection switch
The control box shall permit change between the following modes of operation:

a) Manual selection.
b) Manual selection with automatic verification.
c) Automatic selection.

Selection of each mode of operation shall be by external means which should prevent unauthorized
adjustment.

6.2 Manual selection

A means for the manual selection of fusion times up to 999 s shall be provided. This shall be suitable for
operation by a gloved operator and shall be inactive during the fusion operation.

6.3 Manual selection with automatic verification

6.3.1 The control box shall be fitted with a means for the manual selection of fusion times (see 6.2).

6.3.2 The manually selected fusion time shall be confirmed by the control box prior to starting the
fusion operation.

Automatic verification of fusion times shall be achieved in accordance with shroud configurations specified
in BS 7336.

The fusion times are given in BS 7336.

6.4 Automatic selection

6.4.1 The means for manual input of the fusion time shall be inactive when the automatic selection
method is used.

6.4.2 The means of achieving automatic selection shall be as specified in 6.3.2.

7. DOCUMENTATION
Following completion of type approval tests, the Contractor shall compile a data folder which shall include
details of all test results and a set of drawings showing all critical information, i.e. dimensions, components,
assembly techniques, etc. The submission shall be presented in a manner that clearly indicates compliance
with, or variations from, the requirements of this specification and shall provide for signature of the Transco
representative witnessing the tests. Three copies of the data folder shall be submitted to Transco.

8. TEST REOUIREMENTS
8.1 General
The Contractor shall demonstrate compliance with this specification by satisfying the testing schedule given
in Table 4 and obtain type approval after a six month field trial and assessment as specified in 10.2.

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8.2 Free fall test

The control box shall withstand one free fall test from a height of 1 m on to level concrete or steel, as
specified in BS 2011: Part 2.1 Ed Procedure 1, without changing the performance of the control system.

After testing, the control box shall meet the requirements of 4.2, 5.2 and 5.4.

8.3 Bump test

The control box shall withstand the following bump test as defined in BS 2011: Part 2.1 Eb:

a) 1000 bumps at 10 g, 16 ms.

b) 18 bumps at 25 g, 6 ms.

After testing, the control box shall meet the requirements of 5.2 and 5.4.

8.4 Vibration test

8.4.1 The assembled control box and individual PCB shall be capable of withstanding the vibration test
specified in 8.4.2 to 8.4.7 inclusive.

8.4.2 All PCBs shall be subjected to a random frequency search from 20 Hz to 2 kHz at 1 g. The PCB
shall be tested in the plane of normal transportation when fitted into the complete control box The resonant
frequencies shall be identified.

8.4.3 The PCB shall then be subjected to a random endurance sine wave resonant search from 20 Hz to
2 kHz at 1 g, for 60 min, in the plane of normal transportation.

8.4.4 On completion of the tests, no cracking of the PCB, nor loosening of the components mounted on
the PCB, shall be evident. When the PCB is included in a control box, the unit shall perform satisfactorily.

8.4.5 With the assembled control box and input cable in the plane of normal transportation , they shall
be subjected to a random frequency range of 20 Hz to 2 kHz with an ASD of 0.002g 2 / Hz for 90 min. The
frequency giving the largest resonance shall be identified.

8.4.6 The assembled control box and input cable shall be further subjected to a single frequency
vibration test. The frequency shall be that identified in 8.4.5. The test shall be for a duration of 90 min with
an
ASD of 0.002g 2 / Hz .

8.4.7 On completion of the test, the control box shall meet the requirements of this specification.

8.5 Insulation test

The control box and input cable shall be subjected to an insulation test to earth with the 110 V primary
circuit connected as follows:

a) Active control elements (e.g. thyristors or triacs) shall have all terminals shorted together.
b) Where applicable, switches, circuit breakers, contactors shall be closed, and fuses shall be
in.
c) Both poles of the supply shall be connected together.

A nominal test voltage of 500 V dc shall be applied between supply poles and earth, and the insulation
resistance thus measured shall be not less than 1 MΩ .

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9. OUTPUT CABLE
9.1 General
9.1.1 All materials used in the construction of output cable shall be suitable for use at ambient
temperatures in the range − 50 C to 40 0 C . The output cable/insulation shall be PVC to BS 6746, Type TI1
with a PVC cable sheath to Type TM1 and flexible conductors to BS 6360.

9.1.2 The nominal length of the cable shall be 3 m. Terminations shall be fitted for de-mountable
connection to the control box at one end and to the electrofusion fitting at the other. The connection to the
electrofusion fitting shall be in accordance with shroud configurations specified in BS 7336. It shall not be
possible to connect a 40 V fitting to an 80 V output, and vice versa, even with a fault in any single system
element.

9.1.3 The contact resistance of the power contacts after 10 000 mating cycle operations shall be not
greater than 10 mΩ .

9.1.4 The connection to the electrofusion fitting shall cause the power contacts to be engaged before
the sensing contacts, and the sensing contacts to be disengaged before the power contacts.

9.1.5 The power cores shall have a maximum voltage drop of 2.0 V ac rms (lead and return) when
measured at a maximum current of 60 A.

9.1.6 For 80 V operation, the output cable shall have overall screening from the plug to the fitting
connector. The screening shall be securely attached to the terminations.

9.1.7 For 80 V operation, the output cable shall be protected by a 30 mA RCCB within the control box
which shall be easily accessible for resetting.

9.1.8 Where a control box is designed solely for use with the Transco rotary switch recognition system,
the connector at the control box shall be as given in Table 5 a) or 5 b). Where a control box is designed for
use with a number of recognition systems including the Transco design, an alternative cable to control box
connector can be used provided the control box can automatically identify the type of fitting recognition
system in use.

9.1.9 Where any other shroud recognition system is used, the cable to box termination shall be unique
to that system in order to prevent incorrect cable to box assembly.

9.1.10 The cable/box connectors shall have an enclosure rated at IP 44 to BS 5420.

9.1.11 The connectors shall be designed with a relief mechanism to prevent straining of the cables
within the harness.

9.1.12 The fitting connector shall be designed to prevent the engaging end of the connector from
splaying out (i.e. increasing in diameter) when the connector is separated from the fitting by pulling at an
angle of not less than 20 0 .

9.1.13 The output cable and fitting connector shall comply with the requirements specified in 9.1.1
to 9.1.12 inclusive and satisfy the testing requirements specified in Appendix D.

9.2 Manual selection

9.2.1 The cable supplied for use with manual selection shall be suitable for the following functions:

a) To supply electrical power to 40 V fittings only.

b) Sensing and feedback of output voltage at the fitting terminal power pin. The voltage
sensing facility shall be isolated from a) above.

9.3 Automatic selection/verification

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9.3.1 The cable supplied for use with automatic selection or manual selection with automatic
verification shall be suitable for the following functions:

a) To supply electrical power to the fitting.

b) Sensing and feedback of output voltage at the fitting terminal power pin. The voltage
sensing facility shall be isolated from a) above.
c) Automatic fitting recognition.

9.3.2 Where switch mechanisms are used in the identification circuit, these shall be subjected
to 10 000 cycles of operation. All fusion times shall then be correctly identified.

10. TESTING
10.1 General
Tests carried out on control boxes shall be in two parts:

a) Type approval testing (see 10.2).

b) Batch acceptance testing (see 10.3).

No control box shall be marketed within Transco until the tests given in Tables 4 and 8 have been carried
out and approval granted in writing by Transco. The Contractor shall obtain the approval of Transco for all
changes in his sub-contractor's materials, and/or changes in design.

10.2 Type approval testing

10.2.1 The Contractor shall demonstrate compliance of his control box design with this specification by
carrying out the schedule of type approval tests given in Table 4.

10.2.2 The output cable and fitting connector shall withstand an axial pull of 100 N without failure or
deterioration, and the fitting connector shall meet BS 5420 IP 67.

10.2.3 Following the contact resistance test (see 9.1.3), the control box and output cable shall be
connected in turn to fittings in each of the configurations specified in BS 7336. Each fusion time shall be
correctly identified. The Contractor may alternatively demonstrate the same identification using a suitable
test rig.

10.2.4 The control box shall be tested at 23 0C under the conditions given in Table 6.

The output voltage shall be measured and shall be in the range 39 V ac rms to 40 V ac rms (see 5.2). The
timer accuracy shall be measured during each test and shall be within ± 0.5% of set point (see 5.4).

10.2.5 The self-heating of the control box shall be tested under the conditions given in Table 7.

The temperature of the critical electrical/electronic components shall be continuously monitored during the
test and shall not go above the maximum temperature specified by the component manufacturer.

10.2.6 The latching current of the individual triac used in the control box shall be measured in both
directions at 20 0 C . For an inverse parallel thyristor arrangement, both thyristors should be measured. The
higher of these two values shall be considered ( I 1 ) The thyristor manufacturer's data sheet will quote the
maximum latching current at 20 0 C ( I 2 ). Generally, at − 10 0 C the latching current of a thyristor will
increase by up to 50% over its value at 20 0 C .

The trigger pulse should be shortened to t p where:

I1 2
tp = × t1 × or, where t p < t min , then
I2 3
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t p = t min = minimum trigger pulse of device

and t 1 = standard control unit pulse width.

With the shortened pulse, the control box shall supply power to a 60 A load, when powered by any
generator in use by Transco or its contractors. Using a transient recorder, or similar fast recording device,
the output voltage waveform should be monitored during the start of the fusion cycle. No missing half
cycles should be detected during this period.

10.2.7 With the control box operating under full-load conditions and an RCCB connected to the input
supply, a fault current equal to the rated trip current of the RCCB shall be introduced. The RCCB shall
operate within the rated trip time.

10.3 Batch acceptance testing

10.3.1 Once type approval to this specification has been granted, the production batches of control boxes
shall be tested in accordance with Table 8.

A batch shall be a maximum of 100 control boxes.

10.3.2 Control boxes shall be tested under both of the conditions given in Table 9, when testing for
output voltage and timer accuracy.

10.3.3 The control box and output lead shall be connected in turn to fittings in each of the configurations
specified in BS 7366. Each fusion time shall be correctly identified. The Contractor may alternatively
demonstrate the same identification capability using a suitable test rig.

10.3.4 The control box shall be operated for 30 min at minimum rated output current.

10.3.5 10% of every batch shall be operated for 30 min at maximum rated output current before
dispatch.

11. VARIANTS
A contractor shall only propose variants to this specification where the text indicates that variants would be
considered by Transco.

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TABLE 1 - Operating parameters

TABLE 2 - Duty Cycle

TABLE 3 - Trip settings for output voltage

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TABLE 4 - Schedule of type approval tests

Table 4 a) - Control box

Table 4 b) - Output cable

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TABLE 5 - Connector types

TABLE 5 a) - Connectors to BS 9522 F0032

TABLE 5 b) - Connectors to VG 95234 Teil 3

TABLE 6 - Test conditions at 23 OC

TABLE 7 - Self-heating test conditions

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TABLE 8 - Schedule of batch acceptance tests

Table 8 a) - Control box

Table 8 b) - Output cable

TABLE 9 - Test conditions

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APPENDIX A
DATA LOGGING AND RETRIEVAL (OPTIONAL)
If required by Transco, the control box shall have the facility for the logging and retrieval of the following
data in an agreed format:

For every box

a) Control box identification number.
b) A minimum of 1024 entries.

An alarm facility shall be provided to indicate when the log memory is 95% full to enable the operator to
down-load the data to a printer.

If the alarm is ignored, the data entries shall be overwritten commencing with the oldest entry.

For every joint

c) Joint serial number.
d) Date and time joint made.
e) Fusion time.
f) Status of joint.

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APPENDIX B
SPECIFIC REQUIREMENTS AND TESTING FOR COMBINED ELECTROFUSION CONTROL AND
POWER GENERATION SYSTEMS
B.1 REQUIREMENTS
B.1.1 The power generation system shall meet the requirements of ECE3.

B.1.2 For a 2 kW unit, a changeover switch shall be provided to select either electrofusion (40V) or
110 V, 16 A output.

For a 3 kW unit, a changeover switch shall be provided to select electrofusion (40 V) or 110 V, 16 A or
110 V, 32 A output.

For a 6 kW unit, a changeover switch shall be provided to select either electrofusion or 110 V, both 16 A
and 32 A, output. If appropriate, a further changeover switch shall be provided to select either 40 V or 80 V
electrofusion output. The lighting output (fused at 5 A) shall be continuously available.

B.1.3 The generation unit may be directly connected to the control box.

B.1.4 The Contractor shall supply, as an option, a remote portable start/stop unit with a means of
inputting and displaying the fusion time. The remote unit shall be attached to the control box by means of a
polyvinyl chloride (PVC) metal-screened cable. The cable length shall be 6 m. The remote STOP button
shall be in series with the main STOP button on the control box (see 4.8).

B.1.5 The mid-point of the 110 V and 80 V (as appropriate) windings shall be taken to a zero potential
earth, i.e. centre-tapped earth outlets.

One side of the 40 V winding may be earthed.

B.1.6 The nominal length of the electrofusion output cable shall be 6 m.

B.1.7 The power cores shall have a maximum voltage drop of 4.0 V ac rms (lead and return) when
measured at a maximum current of 60 A.

B.1.8 The control box shall meet the requirements of BS 833 for radio frequency interference
suppression.

B.2 TESTING
B.2.1 Approval tests
B.2.1.1 Approval testing of the 110 V system shall be in accordance with ECE3, clause 6.2.

B.2.1.2 The combined unit shall be tested under the conditions specified in Table B1.

B.2.1.3 The combined unit shall meet the requirements of the following tests:

a) Bump test to 8.3

b) Vibration test to 8.4.
c) Weather protection to 4.2.

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B.2.2 Acceptance tests

B.2.2.1 Acceptance testing of the 110 V system shall be In accordance with ECE3, clause 6.3.

B.2.2.2 The combined unit shall be tested under the conditions specified in Table B2.

TABLE B1 - Test conditions for approval testing

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TABLE B2 - Test conditions for acceptance testing

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APPENDIX C
LIST OF REFERENCES
This specification makes reference to the documents listed below. Unless otherwise specified the latest
editions of these documents, including all addenda and revisions, shall apply.

British Standards

BS 833 - Specification for radio interference limits and measurements for the
electrical ignition systems of internal combustion engines

BS 2011 - Environmental testing:

Part 2.1 Eb - Test Eb. Bump
Part 2.1 Ed - Test Ed. Free fall

BS 2754 - Memorandum. Construction of electrical equipment for protection

against electric shock

BS 3535 - Isolating transformers and safety isolating transformers

BS 4343 - Specification for industrial plugs, socket-outlets and couplers for a.c.
and d.c. supplies

BS 4884 - Specification for technical manuals

BS 5420 - Specification for degrees of protection of enclosures of switchgear

and controlgear for voltages up to and including 1000 V a.c. and
1200V d.c.

BS 5750 - Quality systems

BS 6360 - Specification for conductors in insulated cables and cords

BS 6746 - Specification for PVC insulation and sheath of electric cables

BS 7336 - Specification for polyethylene fusion fittings with integral heating

element(s) for use with polyethylene pipes for the conveyance of
gaseous fuels

BS 9522 F0032 - Detail specification for multi-contact circular electrical connectors.

Environmental category: 55/125/56.
Full assessment level

German Standard (Bundesamt fur Wehrtechnik und Beschaffung)

VG 95234 - Elektrische Steckverbinder mit Bajonettkupplung druckwasserdicht

Teil 3 bis 245 A bis 40 V

Transco specifications

ECE3 - Specification for transportable electricity generator sets including

generators combined with compressors

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EL3 - Transco joint engineering and marketing requirements for

IM/113 the selection, protection, maintenance and operation of
electrically-operated portable and transportable tools and equipment

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APPENDIX D
ENVIRONMENTAL TESTING OF ELECTROFUSION CONNECTOR
D.1 Two connectors shall be subjected to accelerated life testing.

D.2 The power pin used in the tests shall have an initial surface finish not better than 32µm CLA
(N7), and its diameter for the duration of the tests shall be within 4.68 mm to 4.73 mm for 40 V and 5.69
mm to
5.74 mm for 80 V.

D.3 The accelerated life cycle test shall consist of:

a) Engagement of keyway.
b) Rotation of switch through 1 1 2 revolutions (where applicable).
c) Engagement onto the power pin.
d) The connector shall then be energized to pass 60 A for 60s. The voltage sense circuit shall
be made.
e) The connector shall be broken from the power pin at 0 V.

D.4 The voltage drop across the power contact shall be measured after completion of 0, 50, 100, 500,
1000, 2500, 5000 and 10 000 cycles. At these times, the power pin diameter shall be recorded and replaced
if necessary.

D.5 One assembly shall be thermally cycled, during the life testing, between − 10 0 C and + 40 0 C at a
duty cycle of 3h.

D.6 The second assembly shall be immersed in a mud/water solution for 24 h and allowed to dry for a
further 24 h. The operation of the connector shall be checked and, if necessary, the connector shall be
cleaned by immersion in cold clean water for one minute. The tests listed above shall be carried out at
ambient temperature. The assembly shall be re-immersed in the mud solution and dried after intervals of 0,
500, 1000, 2500 and 5000 cycles.

D.7 After completion of the tests, the power pin contact resistance shall not exceed 10 mΩ . The
continuity of the voltage sense circuit shall be measured.

J236 (Rev 11/02) - 19 -