IEC 61238-1-1:2018

Overview

IEC 61238-1-1:2018 is an International Electrotechnical Commission (IEC) standard that specifies test methods and requirements for compression and mechanical connectors for power cables rated up to 1 kV (Um = 1.2 kV) when tested on non‑insulated conductors. It covers connectors for copper conductors with nominal cross-sectional areas from 2.5 mm² to 1 200 mm² and aluminium conductors from 16 mm² to 1 200 mm², with a maximum continuous conductor temperature of 90 °C. The standard excludes connectors for overhead line conductors and connectors using sliding contacts. Tests are performed on unused conductors as the reference method.

Key Topics and Requirements

• Scope and conductor limits: Defines applicable conductor materials (copper, aluminium), cross-sections and temperature limits for power-cable connectors.
• Test methods: Establishes procedures for electrical and mechanical evaluation, including:
  • Electrical resistance measurements and temperature monitoring.
  • Heat‑cycling tests to assess connector stability under thermal stress.
  • Short‑circuit testing, with updated calculation methods and requirements to verify connector integrity under fault current conditions.
  • Mechanical tests (tensile/elongation) to verify mechanical performance and newly introduced mechanical classes for different force conditions.
• Classes and range of approval: Defines connector classes (including two new mechanical classes) and rules for range approval across conductor sizes.
• Test configuration and reporting: Specifies test loop configurations, measurement positions, assessment methods and minimum reporting content.
• Updated safeguards: Limits on maximum elevated heating current during electrical tests to avoid unrealistic current densities that could alter connector properties.

Applications and Who Uses This Standard

IEC 61238-1-1 is used in practical contexts where reliable, certified cable connections are critical:

• Connector and cable manufacturers for product development, type testing and quality assurance.
• Independent test laboratories performing compliance and certification testing.
• Utilities, contractors and specifiers selecting connectors for buried, building or installation applications up to 1 kV.
• Certification bodies and procurement teams defining acceptance criteria and technical specifications.

Keywords: IEC 61238-1-1, compression connectors, mechanical connectors, power cables, test methods, short-circuit test, heat cycling, electrical resistance, 1 kV.

Related Standards

• IEC 61238-1-2 and IEC 61238-1-3 (parts of the same series)
• IEC 61238-1:2003 (this edition cancels/replaces it)
• IEC 60228 (conductor specifications referenced in scope)