EDR-5498, Rev.

C
Material Qualification of Red and Gray MVCC Line
Covers to PPS 3010/61

Material Qualification of Red and Gray MVCC Line Covers to PPS 3010/61

Title: Pages: 11

EDR-5498, Rev. C January 7, 2021

Report Number: Date:

Prepared By:
Robert Kyles
(Development Engineer) January 7, 2021

Signature Date:
Approved By:
Luis Puigcerver
(Product Manager) January 7, 2021

Signature Date:

TE Connectivity EDR-5498, Rev.C

8000 Purfoy Road
Fuquay-Varina, NC 27526
 TABLE OF CONTENTS

1. OBJECTIVE ............................................................................................................................2

2. SUMMARY..............................................................................................................................2

3. MATERIAL AND SAMPLE PREPARATION ...................................................................2

4. TEST PROCEDURES ............................................................................................................2

5. RESULTS.................................................................................................................................6

6. DISCUSSION ..........................................................................................................................7

7. CONCLUSION ........................................................................................................................8

APPENDIX I: THERMAL ENDURANCE ANALYSIS............................................................9

APPENDIX II: REVISION HISTORY .....................................................................................11

TE Connectivity 1 EDR-5498, Rev.C

8000 Purfoy Road
Fuquay-Varina, NC 27526
1. OBJECTIVE

This report documents the evaluation of the rubber compounds used for the red and gray
Medium Voltage Conductor Covers (MVCC), after a formulation change was made in each
compound. These materials were subjected to physical, chemical, electrical, and accelerated
aging tests to determine their ability to resist thermal aging, flammability and weathering.

The tests for the MVCC material qualification program were performed in accordance with TE
Connectivity internal compound specification document, Product Performance Specification PPS
3010/61.

2. SUMMARY

The MVCC line cover was developed to be a flexible cold applied solution to improve flashover
protection for medium voltage bare conductors in a substation. The MVCC line cover is
intended to prevent flashovers such as phase to phase contact or incidental contact with animals
or trees.

3. MATERIAL AND SAMPLE PREPARATION

Testing was performed on red and gray MVCC material, either from product cut in the extruded
direction or on compression molded plaques, as appropriate for each test. Plaques were
compression molded from un-cured red and gray MVCC compound, T719-2 & -8 respectively,
for 10 minutes at 121oC and then post-cured for 4 hours at 177oC.

4. TEST PROCEDURES

Tensile and Ultimate Elongation

Five ASTM D412 type D test specimens were cut for each of gray and red MVCC. The tensile
strength and ultimate elongation tests were conducted according to ASTM D638 with an initial
grip separation of 2 inches and a rate of separation of 20 inches per minute.

Density
Density was determined using a Mettler Density Detector in accordance with ASTM D792.
Three test specimens were cut from product of each color of MVCC and tested using methanol
as the immersion liquid.

Accelerated Aging
Five ASTM D412 type D test specimens were cut from gray and red MVCC material. The test
specimens were hung in a forced air oven at 150C for 168 hours. After 168 hours, the test
specimens were removed and allowed to cool to room temperature, visually examined, and tested
for tensile strength and ultimate elongation. The tensile strength and ultimate elongation tests
were conducted with an initial grip separation of 2 inches and a rate of separation of 20 inches
per minute in accordance with ASTM D638.

TE Connectivity 2 EDR-5498, Rev.C

8000 Purfoy Road
Fuquay-Varina, NC 27526
Thermal Endurance
ASTM D412 type D test specimens from gray and red MVCC were vertically hung in forced air
ovens at 200oC, 175oC, and 150oC. Groups of five specimens were removed at selected times
and measured for tensile strength and ultimate elongation.

The tensile strength and ultimate elongation measurements were performed according to ASTM
D638 with an initial grip separation of 2 inches and a rate of separation of 20 inches per minute.
The thermal endurance was determined according to IEC 60216 using 75% ultimate elongation
as the design end-of-life criteria.

See Appendix I for thermal endurance curves.

Low Temperature Flexibility

Three 6” X 1/4” samples of red and gray MVCC material were placed into a (-20±3)oC freezer
along with a 1.06” diameter mandrel. After 4 hours and without removing the mandrel or test
specimens from the chamber, each test specimen was wrapped 360 degrees around the mandrel
within 10±2 seconds. The test specimens are then removed from the cold chamber and visually
examined for cracks.

Dielectric Strength
Dielectric strength testing was performed in accordance with ASTM D149 on three points on a
6” X 6” compression molded plaque of gray and red MVCC line cover material with nominal
thickness of 0.080”. A Haefely AC Dielectric Test Set Model 750-10 set at 750 volts/second
automatic rate of rise was monitored and the breakdown voltage recorded for each test specimen.

Volume Resistivity
Volume resistivity testing was performed on three compression molded plaques of gray and red
MVCC material with nominal thickness of 0.080”. A 3.05” diameter piece of adhesive backed
aluminum foil tape was placed on both the top and bottom surface of each plaque to provide
electrodes. The resistance was measured using 2-inch electrodes and an AEMC Model 1060
Megohmmeter with a test voltage of 500V. The resistance values were recorded after a
minimum of 1 minute electrification. The volume resistivity for each test specimen was
calculated as follows:

ρ (Ohm-cm) = R (Ohm) * A (cm2)/h(cm)

ρ = Volume Resistivity
R = Resistance
A= Area
h = Thickness

TE Connectivity 3 EDR-5498, Rev.C

8000 Purfoy Road
Fuquay-Varina, NC 27526
Dielectric Constant
Dielectric constant measurements were performed according to ASTM D150 on three
compression molded plaques of gray and red MVCC line cover material with a nominal
thickness of 0.080”. A 3.05” diameter piece of adhesive backed aluminum foil tape was placed
on both the top and bottom surface of each plaque to provide electrodes. The capacitance was
measured using 2-inch electrodes and Multi-Amp 810130 C & DF Bridge, model CB100. From
the bridge, the capacitance was recorded and the dielectric constant was calculated as follows:

ε = C/ε0 (Thickness/Area)
C = Capacitance
ε = dielectric constant of material
ε0 = dielectric constant of
vacuum (8.85 x 1012F/M)

Tracking and Erosion Resistance

Tracking and erosion resistance tests were performed in accordance with ASTM D2303. Five 2”
X 5” compression molded samples were cleaned with isopropanol, rinsed with distilled water,
lightly sanded with 400 grit wet silicon carbide sandpaper, and then finally rinsed again with
distilled water. The area underneath the bottom electrode was painted with silver conductive
paint.

The tracking and erosion resistance was obtained according to the variable voltage method. In
this method, the applied voltage and contaminant solution flow rate were varied over a specified
time period. The conductivity of the contaminant solution was between 2500-2700 µS/cm at
23oC.

The voltage and the contaminant flow rates are seen in Table 1 below.

Time Voltage Contaminant flow rate Series Resistor

(min) (kV) (ml/min) (Ω)
0-60 2.50 0.15 ±0.01 10,000
60-120 2.75 0.15 ±0.01 10,000
120-180 3.00 0.30 ±0.02 50,000
180-240 3.25 0.30 ±0.02 50,000
Table 1: Test Conditions for tracking and erosion resistance test.

Water Absorption
Water absorption testing was performed in accordance with ASTM D570. Three 3” X 1”
samples were cut from gray and red MVCC material and dried at 110oC for 1 hour in a forced-air
oven. After 1 hour the specimens were removed and allowed to cool in a desiccator and were
weighed (initial weight) to the nearest 0.001g. The test specimens were then immersed in a
container of distilled water maintained at 23  1C. After 336 hours, the specimens were
removed from the water, wiped dry, and immediately weighed to the nearest 0.001g.

TE Connectivity 4 EDR-5498, Rev.C

8000 Purfoy Road
Fuquay-Varina, NC 27526
Resistance to Bird Excrement
Five ASTM D412 type D samples, cut from gray and red material, were immersed in an acidic
solution of 50 grams uric acid in 65 ml of water at 60oC. After 168 hours the test specimens
were removed from the test fluid, lightly wiped dry, and air dried for 45±15 minutes at room
temperature. Once dry, the specimens were tested to determine tensile and ultimate elongation
properties. The tensile strength and ultimate elongation measurements were performed according
to ASTM D638 with an initial grip separation of 2 inches and a rate of separation of 20 inches
per minute.

Resistance to Conductor Cable Grease

Five ASTM D412 type D samples, cut from gray and red material were placed into a petri dish.
Burndy Penetrox Grease “Item No. 547046” was liberally applied to the surface of the test
specimens. The coated samples were placed in a 60oC forced air oven for 168 hours. After 168
hours the test specimens were removed from the test fluid, lightly wiped clean, and allowed to
equilibrate 45±15 minutes at room temperature. Once cool, the specimens were tested to
determine tensile and ultimate elongation properties. The tensile strength and ultimate elongation
measurements were performed according to ASTM D638 with an initial grip separation of 2
inches and a rate of separation of 20 inches per minute.

Additional Testing
In addition to the above PPS testing, UV resistance and UL94 50W Vertical Flammability testing
was performed on MVCC material.

UV Resistance: 3” X 6” samples of both gray and red MVCC materials were placed into a UVA
weathering chamber equipped with UVA-340 lamps. The testing was performed for 6400 UV
hours according to ASTM G154 with a repetitive cycle of 8 hours UVA at 60oC followed by 4
hours of condensation at 50oC. Test plaques were periodically removed from the test chamber
and tensile strength and ultimate elongation properties were measured. Tensile and elongation
test specimens were cut using an ASTM D412 die and testing was performed at room
temperature with an initial grip distance of 2 inches and a rate of separation of 20 inches per
minute according to ASTM D638.

UL94 50W Vertical Flammability: The specimens were tested per UL 94 Section 8, 50W
Vertical Burning Test. Samples were preconditioned in an air-circulating oven for 168 hours at
70°C and then cooled in a desiccator for > 4 hours at room temperature. Cotton placed below the
samples was conditioned in a desiccator for > 24 hours prior to use. Testing was performed
within 30 minutes after removing materials from the desiccator. A burner with a blue flame
20mm high approached the specimen horizontally from the wide face. The flame was applied
centrally to the bottom of the specimen and maintained 10mm below for 10 seconds. It was then
withdrawn away from the specimen when the afterflame time, t1, was recorded. The flame was
placed again under the specimen for another 10 seconds, and then withdrawn away when the
afterflame time, t2, and the afterglow time, t3, were recorded.

TE Connectivity 5 EDR-5498, Rev.C

8000 Purfoy Road
Fuquay-Varina, NC 27526
5. RESULTS

The following properties were evaluated and passed for MVCC red and gray.

Table 2. Test Results

PROPERTY REQUIREMENT RESULTS

Tensile Strength 200 psi min. PASS
Ultimate Elongation 90% min. PASS
Density (1.5-1.7) g/cm3 PASS
Accelerated Aging
168 hrs. at (1502)C
- Tensile Strength 200 psi min. PASS
- Ultimate Elongation 90% min.
Thermal Endurance 105oC min. PASS

Low Temperature Flexibility No cracking PASS

4 hrs at –(20±3)oC
Dielectric Strength
1.91 mm/0.075 inch wall 300 V/mil min. PASS
Volume Resistivity 1 x 1012 Ohm-cm min. PASS
Dielectric Constant 5.0 max. PASS
Tracking and Erosion Resistance No tracking, erosion to top PASS
surface or flame failure after:
1 hr at 2.5 kv
1 hr at 2.75 kV
1 hr at 3.0 kV
20 min at 3.25 kV
Water Absorption
336 hrs. at (232)C 1% max weight change PASS
Resistance to Bird Excrement
- Tensile Strength 200 psi min. PASS
- Ultimate Elongation 75% min.
Resistance to Conductor Cable Grease
- Tensile Strength 200 psi min. PASS
- Ultimate Elongation 75% min.
UV Resistance See Figure 1
- Tensile Strength N/A >200 psi
- Ultimate Elongation >75%

UL94 50W Vertical Burning N/A V0 Rating

TE Connectivity 6 EDR-5498, Rev.C

8000 Purfoy Road
Fuquay-Varina, NC 27526
Figure 1: UVA resistance results for MVCC red and gray

After 6400 hours of UVA exposure, both the red and gray MVCC materials exhibit greater than
200psi tensile strength and 75% ultimate elongation.

Raw data can be found in laboratory notebooks Nos. 20874, 20876, 20883, 21264, 21269 and
21456.

6. DISCUSSION

• Tensile strength, ultimate elongation, and electrical results indicate the material has adequate
physical and electrical properties for MVCC.

• The red and gray MVCC materials have satisfactory electrical performance for this
application. Tracking and erosion resistance tests exhibited no failures within the first 200
minutes of testing.

• MVCC products may come into contact with pollution, conductor cable grease or natural
deposited chemicals such as bird excrement. These chemicals can react with the materials in
which they come into contact with and affect overall product lifetime and performance. The
MVCC proved resistant to chemicals it may come into contact with during its lifetime.

• Thermal Endurance tests are important in discovering how well a material will age. A level
of 75% ultimate elongation was selected as the design end-of-life criteria. An elongation of
75% will provide more than adequate elongation for the product to remain functional. Linear

TE Connectivity 7 EDR-5498, Rev.C

8000 Purfoy Road
Fuquay-Varina, NC 27526
 regression analysis of the plotted data shows that the red material can be thermally aged for
20,000 hrs at 115oC and the gray material at 128oC and still exhibit 75% ultimate elongation.

• MVCC products show excellent stability to the effects of UVA radiation. The red and gray
materials exhibit greater than 75% ultimate elongation after 6400 hours of UVA exposure.

• MVCC products exhibit excellent flammability resistance, achieving a V0 rating in the UL94
50W vertical burning test.

7. CONCLUSION

The red and gray MVCC materials meet existing requirements outlined in material specification
PPS 3010/61. Test results indicate the MVCC materials exhibit an adequate degree of physical,
thermal, UV, chemical, and electrical properties for this product application.

TE Connectivity 8 EDR-5498, Rev.C

8000 Purfoy Road
Fuquay-Varina, NC 27526
 APPENDIX I: THERMAL ENDURANCE ANALYSIS

Figure 2: MVCC red and gray ultimate elongation as a function of thermal exposure

TE Connectivity 9 EDR-5498, Rev.C

8000 Purfoy Road
Fuquay-Varina, NC 27526
Figure 3: Thermal endurance analysis for MVCC red and gray

TE Connectivity 10 EDR-5498, Rev.C

8000 Purfoy Road
Fuquay-Varina, NC 27526
APPENDIX II: REVISION HISTORY

Revision Issue Date Description

Original November 6, 2009 Qualification of MVCC to PPS 3010/61
A January 25, 2017 Requalification of MVCC to PPS 3010/61 due to
reformulation of the compound
B May 7, 2020 Addition of long-term UV data point
C January 7, 2021 Addition of UL94 50W vertical burning results and removal
of PPS table.

TE Connectivity 11 EDR-5498, Rev.C

8000 Purfoy Road
Fuquay-Varina, NC 27526