MALAYSIAN MS 1838:2005

STANDARD
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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

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

DEPARTMENT OF STANDARDS MALAYSIA

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 DEVELOPMENT OF MALAYSIAN STANDARDS

The Department of Standards Malaysia (DSM) is the national standardisation and

accreditation body.

The main function of the Department is to foster and promote standards,

standardisation and accreditation as a means of advancing the national economy,
promoting industrial efficiency and development, benefiting the health and safety of
the public, protecting the consumers, facilitating domestic and international trade and
furthering international cooperation in relation to standards and standardisation.
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Malaysian Standards are developed through consensus by committees which

comprise of balanced representation of producers, users, consumers and others with
relevant interests, as may be appropriate to the subject in hand. To the greatest
extent possible, Malaysian Standards are aligned to or are adoption of international
standards. Approval of a standard as a Malaysian Standard is governed by the
Standards of Malaysia Act 1996 (Act 549). Malaysian Standards are reviewed
periodically. The use of Malaysian Standards is voluntary except in so far as they are
made mandatory by regulatory authorities by means of regulations, local by-laws or
any other similar ways.

The Department of Standards appoints SIRIM Berhad as the agent to develop

Malaysian Standards. The Department also appoints SIRIM Berhad as the agent for
distribution and sale of Malaysian Standards.

For further information on Malaysian Standards, please contact:

Department of Standards Malaysia OR SIRIM Berhad

Level 1 & 2, Block C4, Parcel C (Company No. 367474 - V)
Federal Government Administrative Centre 1, Persiaran Dato’ Menteri
62502 Putrajaya P.O. Box 7035, Section 2
MALAYSIA 40911 Shah Alam
Selangor D.E.

Tel: 60 3 88858000 Tel: 60 3 5544 6000

Fax: 60 3 88885060 Fax: 60 3 5510 8095

http://www.dsm.gov.my http://www.sirim.my

E-mail: central@dsm.gov.my
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 MS 1838:2005

CONTENTS

Page

Committee representation …………………………………………………………. ii

Foreword ……………………………………………………………………………… iii

1 Scope …………………………………………………………………………………. 1
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2 Normative reference ………………………………………………………………… … 1

3 Definitions ………………………………………………………………………………. 1

4 Requirements…………………………………………………………………………… 2

Tables

1 Material specification for cable lugs ………………………………………………… 4

2 Finishing specification for cable lugs ………………………………………………… 4

3 Overall installed dimensions for crimp type cable lugs for 1 kV & 36 kV ………… 6

Figures

1 Construction of low voltage application heavy duty cable lug …………………….. 3

2 Construction of medium voltage application heavy duty cable lug ……………….. 3

3 Example of marking on LV cable lugs……………………………………………….. 4

4 Example of marking on MV cable lug………………………………………………… 5

5 Legend showing the dimensions of LV cable lug ………………………………….. 5

6 Legend showing the dimensions of MV cable lug ………………………………….. 6

7 Chamfer on LV cable lug………………………………………………………………. 7

8 Chamfer on MV cable lug …………………………………………………………….. 7

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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:

Association of Consulting Engineers Malaysia

Department of Standards Malaysia
Federation of Malaysian Consumers Association
Federation of Malaysian Manufacturers
Jabatan Kerja Raya
Malaysian Cable Manufacturers Association
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Malaysian Electrical Appliances and Distributors Association

Ministry of Domestic Trade and Consumer Affairs
Ministry of International Trade and Industry
Pusat Tenaga Malaysia
Suruhanjaya Komunikasi dan Multimedia Malaysia
Suruhanjaya Tenaga
Tenaga Nasional Berhad
The Electrical and Electronics Association of Malaysia
The Institution of Engineers, Malaysia
Universiti Teknologi Malaysia

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:

Association of Consulting Engineers Malaysia

EITA Holdings Sdn Bhd

G. H. Liew Engineering (1990) Sdn Bhd

Jabatan Bomba dan Penyelamat Malaysia

Jabatan Kerja Raya

Sabah Electricity Sdn Bhd

Sarawak Electricity Supply Corporation

SIRIM QAS International Sdn Bhd

Suruhanjaya Tenaga

The Electrical and Electronics Association of Malaysia (Secretariat)

The Institution of Engineers, Malaysia

Time Era Sdn Bhd

TNB Distribution Sdn Bhd

Universiti Malaya

Universiti Teknologi Malaysia

ii
 MS 1838:2005

FOREWORD

This Malaysian Standard was developed by the Technical Committee on Electrical

Installation, Protection and Insulation Practice under the authority of the Electrotechnical
Industry Standards Committee. Development of this standard was carried out by The
Electrical and Electronics Association of Malaysia which is the Standards-Writing
Organisation (SWO) appointed by SIRIM Berhad to develop standards for electrical
installation, protection and insulation practice.
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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
2 2
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
2 2
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
2
"undersized" standard lugs used; for example, a 150 mm standard cable lug to MS
2
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.

iii
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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
2 2
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 60228, Conductors of insulated cables

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

For the purposes of this standard, the following definitions apply.

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

3.2 Cable lug

Connector comprising a palm and a connector barrel, for connecting a conductor to an

equipment terminal. The cable lug mentioned in this standard, applies to crimp type cable
lugs for low voltage & medium voltage applications.

3.3 Palm

Part of a cable lug used to make the connection to equipment terminals.

3.4 Connector barrel

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Part of a connector, into which the conductor to be connected is introduced.

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

Method of securing a connector to a conductor by using a special tool to produce permanent

deformation of the connector and the conductor.

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.

2
 MS 1838:2005
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Figure 1. Construction of low voltage application heavy duty cable lug

Figure 2. Construction of medium voltage application heavy duty cable lug

(Remark: Remove all sharp edges)

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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.

Table 1. Material specification for cable lugs

Description Specification
Material type Copper
Grade of copper Electrolytic Copper (ETP)
a
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Electrical conductivity of copper 99 % IACS

Purity of copper 99.9 %
a
IACS - International Annealed Copper Standard

4.2.2 The finishing for cable lugs shall comply with the specifications given in Table 2.

Table 2. Finishing specification for cable lugs

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.

Figure 3. Example of marking on LV cable lug

4
 MS 1838:2005
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Figure 4. Example of marking on MV cable lug

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.

Figure 5. Legend showing the dimensions of the LV cable lug

5
 MS 1838:2005
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Figure 6. Legend showing the dimensions of the MV cable lug

Dimensions as specified in Figure 5 & 6 are detailed in Table 3.

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:

1. Allow ± 1 % tolerance on all FL, CL and W dimensions.

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.

4. FL & CL will be minimum length.

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 MS 1838:2005

4.4.1 Chamfer on barrel for LV & MV Cable Lug

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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Figure 7. Chamfer on LV Cable lug

Figure 8. Chamfer on MV cable lug

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 Acknowledgements
Ir Rocky Wong Hon Thang (Chairman)
Puan Khong Choy Tai (Secretary)
Ir Looi Hip Peu
Encik Fu Wing Hoong
Ir Chew Shee Fuee
Encik Hamdan Arshad
Ir Chuang Chu Kuen
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Encik Peter Lajumin
Cik Winnie Lim
Encik Mohd Ismail
Ir Fairus Abd Manaf
Ir Faridon Talib
Encik Richard Lew Min Fatt/
Encik Khoo Lin Siang
Ir Halim Osman
Dr Hew Wooi Ping
Prof Dr Hussein Ahmad
The Electrical and Electronics Association of
Malaysia
The Electrical and Electronics Association of
Malaysia
Association of Consulting Engineers Malaysia
EITA Holdings Sdn Bhd
G. H. Liew Engineering (1990) Sdn Bhd
Jabatan Bomba dan Penyelamat Malaysia
Jabatan Kerja Raya
Sabah Electricity Sdn Bhd
Sarawak Electricity Supply Corporation
SIRIM QAS International Sdn Bhd
Suruhanjaya Tenaga
The Institution of Engineers, Malaysia
Time Era Sdn Bhd
TNB Distribution Sdn Bhd
Universiti Malaya
Universiti Teknologi Malaysia