Project Overview
Background, research objectives, and approach of the LV connector accessory project
Heating of Crimp Connectors
Evaluation of one-way to one-way crimp connectors used in low-voltage secondary networks
This research is focused on better understanding the relationship between conditions that can cause heating, the resulting heating that may be identified by IR inspection, and the expected remaining life of the heated connectors. The results of this research will inform field practices and infrared thermography.
This section describes a multi-year project investigating the performance of low voltage (LV) cable accessories. The research has included investigation of the causes of heating in LV connectors and sought data to develop representative secondary connector load versus temperature characteristics. Research included the development of a testing facility at EPRI’s Lenox Laboratory to enable testing of LV connectors under various loading histories and measure the steady state thermal response to develop load characteristics, including the time to heat and temperatures measured with embedded thermocouples and Infrared (IR) imaging.
The research has focused on a one-way to one-way 500 MCM copper (Cu) to 500 MCM Cu crimp type connector used in a low voltage secondary network application. With the help of Con Edison, EPRI prepared 26 different connections for study, including samples with various intentional defects. The connectors were linked in series and connected to a programmable current power supply which enabled EPRI to control and vary the current to simulate various loading and heating conditions. Thermocouples were attached to each of the connections, enabling monitoring and recording of temperatures.
This research seeks to better understand the relationship between loading and temperature based on connector defect type and intentional workmanship variations. The results of this research will inform workmanship methods and provide information for improved interpretation of results from infrared thermographic inspections of low voltage connectors.
Update video describing low voltage connector test facility at EPRI’s Lenox Laboratory.
3002017510: Low Voltage Cable Accessory Research, 2019 Update
3002018974: Low-Voltage Cable Accessory Research, 2020 Update
3002021663: Low Voltage Cable Accessory Research, 2021 Update
3002024696: Infrared Thermography in Underground, 2022 Update
Overheated Connector Examination
Examination of overheated crimp connectors
LV Connector Test Setup
LV connector preparation and setup for testing
LV Connector Findings
Current findings on LV connectors
Future Research
What are our next options?
References
References for LV cable accessory research