TECHINICAL INFORMATION

IEC 61238-1 Compression and Mechanical Connectors for Power Cables

for rated voltages up to 30 kV (Um = 36 kV).
DONG-A Terminal Lug "PPIO & PPIT" type, PPEO & PPET Type(see page E4~E15) are complied with
IEC61238-1 requirements and they have been carried out the tests according to "Class A" of IEC61238-1.

1. Scope and object of IEC61238-1

Compression and mechanical connectors for power cables for rated voltages up to 30kV(Um=36kV),
e.g. burried cables or cables installed in buildings, having
a) conductors complying with IEC60228 and IEC60228A with cross-sectional areas 10mm2 and
greater for copper and 16mm2 and greater for aluminum,
b) a maximum continuous conductor temperature not exceeding 90

Class A
These are connectors intended for electricity distribution or industrial networks in which they can be subjected
to short-circuits of relatively high intensity and duration. As a consequence, Class A connectors are suitable
for the majority of applications.

Class B
These are connectors for networks in which overloads or short-circuits are rapidly cleared by the installed
protective devices, e.g. fast-acting fuses.

Depending on the application, the connectors are subjected to the following tests :
Class A : heat cycle, short-circuit tests and mechanical tests.
Class B : heat cycle tests only.

2. IEC 61238-1 Class A Test Process.

Installation : All conductors of the same cross-sectional area in the test loop shall be taken from the same
continuous core and installed in a location where the air calm and the ambient temperature
between 15 and 30

Typical test circuit for through connectors and terminal lugs

Heat Cycle Test - Total 1000 cycles required.

- First heat cycle :
Current is circulated in the test loop, bringing the reference conductor to 120 at equilibrium.
Equilibrium is defined as the moment when the reference conductor and the connectors do not vary in
temperature by more than 2 K for 15 min.if the temperature of the median connector is equal to or greater
than 100 the reference conductor temperature for subsequent heat cycles shall be deemed to be 120
if not, then the current shall be increased until the median connector temperature reaches 100 at
equilibrium, subject to the reference conductor temperature not exceeding 140 If the temperature of the
median connector does not reach 100 even with a reference conductor temperature of 140 the test
shall be continued at that temperature.

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 TECHINICAL INFORMATION
- Second heat cycle :
The second heat cycle is to determine the heat cycle duration and temperature profile which will be used on the
test loop for all subsequent heat cycles. Current is circulated in the loop until the main reference conductor
temperature reaches the value determined in first heat cycle, with a tolerance of +6/0 K and the median
connector temperature is stable within a band of 2K over a 10 min period.
An elevated current may be used to reduce the heating period.

Nominal conductor Al 16 A 50 50 A 150 150 A 630 A 630

cross-sectional area, A mm Cu 10 A 35 35 A 95 95 A 400 A 400
2

Time min 5 10 15 20

- Subsequent heat cycles :

Measurements shall be made at the following cycles (Class A).
0 (before the first heat cycle)
200 cycles, before short-circuit
200 cycles, after short-circuit
250
Then every 75 cycles
(in total 14 measurements)

Short-circuit tests (for Class A connectors only).

Six short-circuits are applied after the 200th heat cycle.
The short-circuit current level shall be such that it raises the bare reference conductors from a temperature
of 35 to a temperature between 250 and 270
The maximum temperature, time and approximate current, or the actual current and time, used for the short-circuit
test, shall be recorded and stated in the test report. After each short-circuit, the test loop shall be cooled to a
temperature 35

Mechanical Tests.
The conductor lengths, between connector and tensile test machine jaws, shall be 500mm.
The rate of application of the load shall not exceed 10N per square millimetre of cross-sectional area and per
second up to the value in copper 60 x Aa(mm2) : maximun 20000N, which is then maintained for 1 min.

Quality Products.

Barrel Diameter : Type of conductors -

- compacted.
- non-compacted.
- flexible(class 5 and 6, according to IEC60228)
- number and arrangement of strands.

Color coding on the barrel for easy selection of crimping dies.

Eye-hole(inspection hole)

Quality Approved by DnV(Det Norske Veritas).

Certificate No : E-10595
Application : Cable shoes for installation inside switchboards/ enclosures onboard ships and mobile offshore units.

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 TERMINAL LUG - Comply with IEC61238-1
COPPER CABLES ONLY
Available wire range : IEC standard cables
Material : High Conductivity copper per 99.9% up with Electro-Tin Plated.
Voltage Rating : According to IEC61238-1 up to 30kV (Um 36kV)

ONE-HOLE

Fig 1 Fig 2 Fig 3 Certificate No : E-10595

Wire Range
Dimension (mm)
(mm2) Stud Dies
PART NO. Drawing
Soild / Size W C L No.( )
Stranded FLEX d2 (Min) d1
1-S 2-L 1-S 2-L
PPIO0001.5-xx03 3 3.3
6.5 17
PPIO0001.5-xx04 4 4.3
1.5 1.5 1.8 6
PPIO0001.5-xx05 5 5.4 19
9
PPIO0001.5-xx06 6 6.4 21
PPIO0002.5-xx03 3 3.3 6.5 17
PPIO0002.5-xx04 4 4.3
2.5 2.5 PPIO0002.5-xx05 5 5.4 2.3 6 19
9
PPIO0002.5-xx06 6 6.4 21
PPIO0002.5-xx08 8 8.5 13 25.5 DATT-90
PPIO0004-xx03 3 3.3 TOOL
6.5 19.5
PPIO0004-xx04 4 4.3
4 4 PPIO0004-xx05 5 5.4 3 8 21.5
9.5
PPIO0004-xx06 6 6.4 23.5
PPIO0004-xx08 8 8.5 13 28
PPIO0006-xx04 4 4.3 7.5 21.5
PPIO0006-xx05 5 5.4 11
6 6 3.5 10 26
PPIO0006-xx06 6 6.4
PPIO0006-xx08 8 8.5
15.5 30
PPIO0006-xx10 10 10.5
PPIO0010-xx05 5 5.3 9 30 40
PPIO0010-xx06 6 6.4
13.5 36 46 DCD3-
10 10 PPIO0010-xx08 8 8.4 4.5 15 25 0010C
PPIO0010-xx10 10 10.5
19 41 51
PPIO0010-xx12 12 13
PPIO0016-xx05 5 5.3 11 33 43
PPIO0016-xx06 6 6.4 DCD3-
16 16 PPIO0016-xx08 8 8.4 13.5 5.5 15 25 0016C
39 49
PPIO0016-xx10 10 10.5
19
PPIO0016-xx12 12 13 41 51
PPIO0025-xx05 5 5.3
PPIO0025-xx06 6 6.4 13.5 43 48 Fig1
25 25 PPIO0025-xx08 8 8.4 7 20 25 Fig2
DCD3-
PPIO0025-xx10 10 10.5 0025C Fig3
19 48 53
PPIO0025-xx12 12 13
PPIO0035-xx05 5 5.3
PPIO0035-xx06 6 6.4 15.6 45 50
35 PPIO0035-xx08 8 8.4 8.2 20 25
DCD3-
PPIO0035-xx10 10 10.5 0035C
19 48 53
PPIO0035-xx12 12 13
PPIO0035-xx05-F 5 5.3
PPIO0035-xx06-F 6 6.4
35 17 9 20 25 45 50
PPIO0035-xx08-F 8 8.4 DCD3-
PPIO0035-xx10-F 10 10.5 0035F
PPIO0035-xx12-F 12 13 19 48 53
PPIO0050-xx05 5 5.3
PPIO0050-xx06 6 6.4
50 PPIO0050-xx08 8 8.4 19 9.5 23 35 53 65 DCD3-
PPIO0050-xx10 10 10.5 0050C
PPIO0050-xx12 12 13
PPIO0050-xx05-F 5 5.3
PPIO0050-xx06-F 6 6.4
PPIO0050-xx08-F DCD3-
50 8 8.4 21 11 23 35 53 65 0050F
PPIO0050-xx10-F 10 10.5
PPIO0050-xx12-F 12 13
PPIO0070-xx08 8 8.4
PPIO0070-xx10 10 10.5 22
70 PPIO0070-xx12 12 13 11.5 25 35 64 74 DCD3-
PPIO0070-xx14 14 15 0070C
25
PPIO0070-xx16 16 17
PPIO0070-xx08-F 8 8.4
PPIO0070-xx10-F 10 10.5
PPIO0070-xx12-F 13 24 13 25 35 64 74 DCD3-
70 12 0070F
PPIO0070-xx14-F 14 15
PPIO0070-xx16-F 16 17
( ) Dies No : See detail page E44~E45

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 TERMINAL LUG - Comply with IEC61238-1
HOW TO ORDER
P P I O 0000 - X R 0 0 - X
Barrel I.D / See wire range
Stud Size (i.e. 10=M10, 12=M12 ... etc)
Barrel Length (i.e. 1-CI = standard barrel, 2-CI = Long Barrel)
Serial Number
Product Code (i.e. PPIO = One Hole type, PPIT = Two Hole type)

Wire Range
Dimension (mm)
(mm2) Stud Dies
PART NO. Drawing
Soild / Size W C L No.( )
Stranded FLEX d2 (Min) d1
1-S 2-L 1-S 2-L
PPIO0095-xx08 8 8.4
PPIO0095-xx10 10 10.5
95 PPIO0095-xx12 12 13 25.5 13.5 31 45 70 84 DCD3-
0095C
PPIO0095-xx14 14 15
PPIO0095-xx16 16 17
PPIO0095-xx08-F 8 8.4
PPIO0095-xx10-F 10 10.5
95 PPIO0095-xx12-F 12 13 28 15 31 45 70 84 DCD3-
14 0095F
PPIO0095-xx14-F 15
PPIO0095-xx16-F 16 17
PPIO00120-xx08 8 8.4
PPIO00120-xx10 10 10.5
120 PPIO00120-xx12 12 13 29 15.5 35 45 85 95 DCD3-
0120C
PPIO00120-xx14 14 15
PPIO00120-xx16 16 17
PPIO00120-xx08-F 8 8.4
PPIO00120-xx10-F 10 10.5 DCD3-
120 PPIO00120-xx12-F 12 13 31 17 35 45 85 95 0120F
PPIO00120-xx14-F 14 15
PPIO00120-xx16-F 16 17
PPIO00150-xx08 8 8.4
PPIO00150-xx10 10 10.5
150
DCD3-
PPIO00150-xx12 12 13 32.5 17 35 45 87 97 0150C
PPIO00150-xx14 14 15
PPIO00150-xx16 16 17
PPIO00150-xx08-F 8 8.4
PPIO00150-xx10-F 10 10.5
150 DCD3-
PPIO00150-xx12-F 12 13 35.5 19 35 45 87 97 0150F
PPIO00150-xx14-F 14 15
PPIO00150-xx16-F 16 17
PPIO00185-xx10 10 10.5
PPIO00185-xx12 12 13 DCD3-
185 PPIO00185-xx14 14 15 35.5 19 40 50 93 103 0185C
PPIO00185-xx16 16 17
PPIO00185-xx20 20 21
PPIO00185-xx10-F 10 10.5
PPIO00185-xx12-F 12 13 Fig1
38.5 21 40 50 93 103
DCD3-
185 PPIO00185-xx14-F 14 15 0185F Fig2
PPIO00185-xx16-F 16 17 Fig3
PPIO00185-xx20-F 20 21
PPIO00240-xx10 10 10.5
PPIO00240-xx12 12 13
240 PPIO00240-xx14 14 15 41 21.5 45 55 100 110 DCD3-
16 0240C
PPIO00240-xx16 17
PPIO00240-xx20 20 21
PPIO00240-xx10-F 10 10.5
PPIO00240-xx12-F 12 13
240 14 DCD3-
PPIO00240-xx14-F 15 43.5 23 45 55 100 110 0240F
PPIO00240-xx16-F 16 17
PPIO00240-xx20-F 20 21
PPIO00300-xx10 10 10.5
PPIO00300-xx12 12 13
300 PPIO00300-xx14 14 15 DCD3-
PPIO00300-xx16 16 17 46 24.5 58 68 122 132 0300C
PPIO00300-xx20 20 21
PPIO00300-xx24 24 25
PPIO00300-xx10-F 10 10.5
PPIO00300-xx12-F 12 13
PPIO00300-xx14-F 14 15 DCD3-
300 48 26 58 68 122 132
0300F
PPIO00300-xx16-F 16 17
PPIO00300-xx20-F 20 21
PPIO00300-xx24-F 24 25
PPIO00400-xx12 12 13
PPIO00400-xx14 14 15
400 PPIO00400-xx16 16 17 55 27.5 70 137
DCD3-
20 0400C
PPIO00400-xx20 21
PPIO00400-xx24 24 25
PPIO00500-xx12 12 13
PPIO00500-xx14 14 15
16 60 31 70 150 DCD3-
500 PPIO00500-xx16 17 0500C
PPIO00500-xx20 20 21
PPIO00500-xx24 24 25
PPIO00630-xx12 12 13
PPIO00630-xx14 14 15
630 PPIO00630xx16 16 17 66.5 35.5 80 162 DCD3-
PPIO00630-xx20 20 21 0630C
PPIO00630-xx24 24 25
( ) Dies No : See detail page E44~E45

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 TERMINAL LUG - Comply with IEC61238-1
COPPER CABLES ONLY
Available wire range : IEC standard cables
Material : High Conductivity copper per 99.9% up with Electro-Tin Plated.
Voltage Rating : According to IEC61238-1 up to 30kV (Um 36kV)

TWO-HOLE

Certificate No : E-10595 Fig 2 Fig 3

Fig 1

Wire Range
Dimension (mm)
(mm2) Stud Dies
PART NO. Drawing
Soild / Size W C L No.
Stranded FLEX d2 (Min) d1
1-S 2-L 1-S 2-L
PPIT0010-xx05 5 5.3 9 74.5 84.5
PPIT0010-xx06 6 6.4 16~
13.5 80.5 90.5 DCD3-
10 10 PPIT0010-xx08 8 8.4 44.5 4.5 15 25 0010C
PPIT0010-xx10 10 10.5
19 85.5 95.5
PPIT0010-xx12 12 13
PPIT0016-xx05 5 5.3 11 77.5 87.5
PPIT0016-xx06 6 6.4
PPIT0016-xx08 8 DCD3-
16 16 8.4 13.5 44.5 5.5 15 25 0016C
PPIT0016-xx10 10 83.5 93.5
10.5
19
PPIT0016-xx12 12 13 85.5 95.5
PPIT0025-xx05 5 5.3
PPIT0025-xx06 6 6.4 13.5 87.5 92.5
8.4 DCD3-
25 25 PPIT0025-xx08 8 7 20 25 0025C
44.5
PPIT0025-xx10 10 10.5
19 92.5 97.5
PPIT0025-xx12 12 13
PPIT0035-xx05 5 5.3
PPIT0035-xx06 6 6.4 15.6 89.5 94.5
35 PPIT0035-xx08 8 8.4 8.2 20 25
DCD3-
44.5 0035C
PPIT0035-xx10 10 10.5
19 92.5 97.5
PPIT0035-xx12 12 13
PPIT0035-xx05-F 5 5.3
PPIT0035-xx06-F 6 6.4
35 17 9 20 25 89.5 94.5 DCD3-
PPIT0035-xx08-F 8 8.4 44.5 0035F
PPIT0035-xx10-F 10 10.5
PPIT0035-xx12-F 12 13 19 92.5 97.5
PPIT0050-xx05 5 5.3
PPIT0050-xx06 6 6.4 Fig1
50 PPIT0050-xx08 8 8.4 19 9.5 23 35 97.5 109.5 DCD3- Fig2
44.5
PPIT0050-xx10 10 10.5 0050C Fig3
PPIT0050-xx12 12 13
PPIT0050-xx05-F 5 5.3
PPIT0050-xx06-F 6 6.4
PPIT0050-xx08-F DCD3-
50 8 8.4 21 44.5 11 23 35 97.5 109.5 0050F
PPIT0050-xx10-F 10 10.5
PPIT0050-xx12-F 12 13
PPIT0070-xx08 8 8.4
PPIT0070-xx10 10 10.5 22
70 PPIT0070-xx12 12 13 11.5 25 35 108.5 118.5 DCD3-
44.5 0070C
PPIT0070-xx14 14 15
25
PPIT0070-xx16 16 17
PPIT0070-xx08-F 8 8.4
PPIT0070-xx10-F 10 10.5
PPIT0070-xx12-F 13 24 44.5 13 25 35 108.5 118.5 DCD3-
70 12 0070F
PPIT0070-xx14-F 14 15
PPIT0070-xx16-F 16 17
PPIT0095-xx08 8 8.4
PPIT0095-xx10 10 10.5
95 PPIT0095-xx12 12 13 25.5 44.5 13.5 31 45 114.5 128.5 DCD3-
PPIT0095-xx14 14 15 0095C
PPIT0095-xx16 16 17
PPIT0095-xx08-F 8 8.4
PPIT0095-xx10-F 10 10.5
95 15 31 45 114.5 128.5
DCD3-
PPIT0095-xx12-F 12 13 28 44.5 0095F
PPIT0095-xx14-F 14 15
PPIT0095-xx16-F 16 17
( ) Dies No : See detail page E44~E45

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 TERMINAL LUG - Comply with IEC61238-1
HOW TO ORDER

P P I T 0000 - X R 0 0 - X
Barrel I.D / See wire range

Stud Size (i.e. 10=M10, 12=M12 ... etc)

Barrel Length (i.e. 1-CI = standard barrel, 2-CI = Long Barrel)

Serial Number

Product Code (i.e. PPIO = One Hole type, PPIT = Two Hole type)

Wire Range
Dimension (mm)
(mm2) Stud Dies
PART NO. Drawing
Soild / Size W C L No.
Stranded FLEX d2 (Min) d1
1-S 2-L 1-S 2-L
PPIT00120-xx08 8 8.4
PPIT00120-xx10 10 10.5
120 PPIT00120-xx12 12 13 29 44.5 15.5 35 45 129.5 139.5 DCD3-
0120C
PPIT00120-xx14 14 15
PPIT00120-xx16 16 17
PPIT00120-xx08-F 8 8.4
PPIT00120-xx10-F 10 10.5 DCD3-
120 PPIT00120-xx12-F 12 13 31.5 44.5 17 35 45 129.5 139.5 0120F
PPIT00120-xx14-F 14 15
PPIT00120-xx16-F 16 17
PPIT00150-xx08 8 8.4
PPIT00150-xx10 10 10.5
150
DCD3-
PPIT00150-xx12 12 13 32.5 44.5 17 35 45 131.5 141.5 0150C
PPIT00150-xx14 14 15
PPIT00150-xx16 16 17
PPIT00150-xx08-F 8 8.4
PPIT00150-xx10-F 10 10.5
150 DCD3-
PPIT00150-xx12-F 12 13 35.5 44.5 19 35 45 131.5 141.5 0150F
PPIT00150-xx14-F 14 15
PPIT00150-xx16-F 16 17
PPIT00185-xx10 10 10.5
PPIT00185-xx12 12 13 DCD3-
185 PPIT00185-xx14 14 15 35.5 44.5 19 40 50 137.5 147.5 0185C
PPIT00185-xx16 16 17
PPIT00185-xx20 20 21
PPIT00185-xx10-F 10 10.5
PPIT00185-xx12-F 12 13 DCD3-
185 PPIT00185-xx14-F 14 15 38.5 44.5 21 40 50 137.5 147.5 0185F
PPIT00185-xx16-F 16 17
PPIT00185-xx20-F 20 21
PPIT00240-xx10 10 10.5
PPIT00240-xx12 12 13
240 PPIT00240-xx14 14 15 41 44.5 21.5 45 55 144.5 154.5 DCD3- Fig1
16 0240C Fig2
PPIT00240-xx16 17
20 Fig3
PPIT00240-xx20 21
PPIT00240-xx10-F 10 10.5
PPIT00240-xx12-F 12 13
240 14 DCD3-
PPIT00240-xx14-F 15 43.5 44.5 23 45 55 144.5 154.5 0240F
PPIT00240-xx16-F 16 17
PPIT00240-xx20-F 20 21
PPIT00300-xx10 10 10.5
PPIT00300-xx12 12 13
300 PPIT00300-xx14 14 15 DCD3-
PPIT00300-xx16 16 17 46 44.5 24.5 58 68 166.5 176.5 0300C
PPIT00300-xx20 20 21
PPIT00300-xx24 24 25
PPIT00300-xx10-F 10 10.5
PPIT00300-xx12-F 12 13
PPIT00300-xx14-F 14 15 DCD3-
300 48 44.5 26 58 68 166.5 176.5 0300F
PPIT00300-xx16-F 16 17
PPIT00300-xx20-F 20 21
PPIT00300-xx24-F 24 25
PPIT00400-xx12 12 13
PPIT00400-xx14 14 15
400 PPIT00400-xx16 16 17 55 44.5 27.5 70 181.5 DCD3-
20 0400C
PPIT00400-xx20 21
PPIT00400-xx24 24 25
PPIT00500-xx12 12 13
PPIT00500-xx14 14 15
16 60 44.5 31 70 194.5 DCD3-
500 PPIT00500-xx16 17 0500C
PPIT00500-xx20 20 21
PPIT00500-xx24 24 25
PPIT00630-xx12 12 13
PPIT00630-xx14 14 15
630 PPIT00630xx16 16 17 66.5 44.5 35.5 80 206.5 DCD3-
PPIT00630-xx20 20 21 0630C
PPIT00630-xx24 24 25
( ) Dies No : See detail page E44~E45

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