ANSI C119-4-2004

ffi AI{SI CTT9.4-2004

Ameri catr-National Stand ard for Electric Connectofs_ Connectors for Use Between Alumi n um -t o-Alurni num or Aluminum-to-Copper Conductors

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ANS! C119.4-2004

American National Standard ForElectricConnectors-

V

Gonnectorsfor UseBetween Aluminum-to-Aluminum or Aluminum-to-Gopper Gonductors

Secretariat:

NationalElectricalManufacturersAssociation ApprovedDecember30, 2004

American NationalStandardsInstitute,Inc.

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ANSfC119.+2004

Contents Page

Foreword

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ANS|C119.+2M preparation............. 5.3.4 Connector

.................7

5.3.5 Conneclor installation Cunentcycfetestprocedures

............7 ....................7

6.1 General

.......7

6.2.1 Conductors

.........8

6.2.2 Connec'tors

.........I

6.3 Equalizers..

....................8

6.3.1 Weldedequalizers..

...............8

6.3.2 Compression sleeveequalizers

...............8

6.4 Conductor lengths

.........8

6.5 Control conductor

..........I

6.5.1 Equivalent aluminum/copper conductors 6.5.2 Multiple control conductors.

....................9 ......................9

6.6 Loopconfiguration andlocation

........9

6.6.1 CCTmethod

.......9

6 . 6 . 2 C C S Tm e t h o d . . . . . . .

...............10

6.7 Ambient conditions 6.8 Testcunent 6.8.1 CCTtemperature conditions

......11 .................. 11 .................. 11

6.8.2 CCSTtemperature conditions..............:......

.............. 11

6.8.3 CCTmethodelevated temperature currentstabilization

..............11

6.8.4 CCSTmethodelevated temperature cunentstabilization

...........'11

6.9 Cunentcyleperiod

......11

period......... 6.9.1 Cunentcycle-ON

................ 11

period 6.9.2 CCTcurrentcycle-OFF

...............12

period......... 6.9.3 CCSTcunentcycle.OFF

.......................12

6.10 Measurements....

.........12

6.10.1 Resistance measurements.............. 6.10.2 Temperature measurements.............. 6.1{ Maximum number of cunentcycles

.....13 ..................... 13 ..................14

6.12 Evaluatio i nnt e r v a | . . . . . . . . . . . . . . . . . . 6.12.1 Evaluation by theCCTmethod................

........14 ...............14

6.12.2 Evaluation by theCCSTmethod

..........14

procedures............. Mechanicaltest

........14

7.1 General 7 , 2 T e s tc o n n e c t o r s . . . . . . . . . . . . .

iv

.....14 .................14

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ANS|C119.+2004 7 . 3 P u l l o ut et s t . . . . . . . . . . . . .

......14

7.4 Torquestrength test............ 7.5 Conductor damagetest.............

...........15

Testreport

..........16

..... 15

Tables 1

Testduration

2

Tensile load

3

Tightening torque

.....................6

4

Conductor lengthsfor cunentcycletests..

g .....................

5

Suggested initialtestcunentto raisecontrolconductor temperature 100.C....................... 1o Cunentcycleperiodsfor controlconductors. ..............12

6 7 8

Resistance andtemperature measurement intervals Length of exposed conductor

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........3 ..........5

.................... 13 ................... 16

ANS|C119.+2004

FOfewOfd fihis Foraaord is notpartofAmerican National Standard C11g.4-2OO4.l This standarddescribescunentcycleand mechanicaltests usedto establishperformance characteristics of connectors usedto join aluminum-to-aluminum or aluminumto-copper bareoverheadconductors. This revisionincludesan alternate,acceleratedcurrentcycletest method,henceforthrefenedto as the currentcyclesubmersiontest (CCST).The CCSTmethoddiffersfromthe traditionalcunentcycletest (CCT)in thattestconductors are rapidlycooledby immersionin chilledwaterat the beginningof the 'cunent-OFFcycleand requiresfewer totalcurrent-ONand cunent-OFFcycles.Comparativetestinghas demonstrated that the CCSTmethodwill provideessentiallythe sameperformance test resultsas the traditionalcunentcycletest (CCT)in fewertest cycles.The currentcycletest remainsthe prefenedtest methodrecommended for qualificationof a connector. Thisrevisionincludesan additionalcunent cycletestmethod(CCT)utilizingelevatedtemperature testing for an extraheavyduty connectorcategory,ClassAA. The intentof elevatedtesttemperaturein Class AA testingis to providea betterperformingconnector. Thisstandardwas initiallydevelopedunderthe directionof the Transmission and Distribution Committee of the EdisonElectricInstitute(EEl). Tentativeperformance-type specifications for electrical characteristics wereissuedin jointreportformin 1958by a steeringcommittee of EEIand an advisory committee of manufac{urers on the aluminumconductorresearchproject(EEl Pub.No.59-70,Tentative Specifications for Conneclors for AluminumConductors). Experiencegainedfromextensivetrial usefurtherconfirmedthe performancecriteriaand test conditions of the tentativespecifications and ledto the development of StandardTDJ 162in October1962by a joint committee of EEIandthe NationalEleclricalManufacturers (NEMA).TDJ 162was Association subsequently superseded by thisdocument. The Subcommiftee on OverheadConnectors of theAccreditedStandardsCommittee on Connectors for ElectricUtili$applications, C119,in itsconstantreviewof the publication, continues to seekouttheviews of responsibleusersthat will contributeto the developmentof befterstandards. Suggestions for improvement of thisstandardwill be welcome.Theyshouldbe sentto the National Electrical Manufacturers Association, 1300North17thStreet,Suite1847,Rosslyn,Virginia22209. This standardwas processedand approvedfor submittalto ANSI by the AccreditedStandards Committee on Connectors for Electrical UtilityApplications, C119. Committee approvalof thisstandard doesnotnecessarily implythatall committeemembersvotedfor its approval.At the timeit approvedthis standard, the C119Committeehadthefollowingmembers: DouglasHarms,Chairpetson RonaldLai,Vice Ghairperson VinceBaclawski,Secretary Organizations Represenfed;

Nameof Representative:

AluminumAssociation

Jean-Marie Asselin

EdisonElectricInstitute

WanenHadley DouglasHarms JamesHanis HarryHayes CurtSchultz GeraldWasielewski

VI

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ANS|C119.+2004 DavidWest

v

NationalElectricEnergyTesting,Research& ApplicationCenter

ThomasChampion

NationalElectricalManufacturers Association

BethBruns DavidDembowski RonaldLai FrankMuench GregNienaber FrankStepniak CarlTamm CarlTaylor DavidThompson JamesZahnen

RuralUtilitiesService(RUS)

TrungHiu

TennesseeValleyAuthority

JeffreyNelson

UnderwritersLaboratories, Incorporated

JakeKillinger

Other

StanleyHodgin

The C119.4Subcommittee on Connectors for UseBetweenAluminum-to-Aluminum or Aluminum-toCopperConductors, whichdeveloped the revisionsof thisstandard,hadthefollowingmembersat the timeof approval:

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N

DouglasHarms,Chairperson RonaldLai,Vice Chairperson Mnce Baclawski,Secretary MikeFenetti PieneGuyot WanenC. Hadley TrungHiu BarryJohnson JakeKillinger ThomasMcKoon RichardMorin GregT. Nienaber WalterRomanko CurtSchulE JamesD. Sprecher CarlR.Tamm CarlTaylor Richard(Jetr)J. Waidelich Gerald\Albsielewski DavidWest AllenWlcox JamesZahnen

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AMERICANNATIONALSTANDARD

ANS| C119.4-2004

\,

Gonnectors for Use BetweenAl umi num-to-Alumi num or Aluminum-to€opper Bare OverheadGonductors

. '

1

Scopeand Purpose

1.1

Scope

Thisstandardcoversconnectors usedfor makingelectricalconnections betweenaluminum-to-aluminum or aluminurn-to-copper conduc{ors usedon distribution linesfor electricutility. andtransmission Thisstandardestablishes the electricaland mechanical test requirements for electricalconnectors.This standardis not intendedto recommend operatingconditions or temperatures.

1.2

Purpose

The purposeof thisstandardis to givereasonable assuranoe meetingthe to the userthatconnectors requirements of this standardwill performin a satisfactorymanner,providedthey havebeenproperly seleciedfor the intendedapplication withthe manufacturer's andare installedin accordance recommendations. Theserviceoperatingconditions andthe selectionof the connectorclassis the responsibility of the user. \t

Althoughthereare 12 possiblecombinations classeslistedin thisstandard,it of electricaland mechanical is intendedthatfourto six combinations will meetthe usualrequirements for a givenrangeof conductor sizes.Thisdoesnot,however,prohibitothercombinations.

{.3

Definitions

bolted-typeconnector:A connectorin whichthe contactbetweenthe conductorand the connectoris madeby pressureexertedby one or moreclampingbolts. conductor: Conductingmaterialusedas a carrierof electriccurrent. connector:A devicejoiningtwo or moreconductors to providea continuous electricalpath. range-takingconnector:Connector designedto acceptmultipleconductorsizes. run conductor(main):A continuous conductor fromwhichotherconductors branch. joiningtwo conductorends. splice:A connector

vj

tang (pad):The flat portionof a connectorusedfor electricalconnection. -

tap conductor: A conduc{orthat branchesoff fromthe run conductor. joininga tap conductor tap connector:Connector withoutbreakingthe run conductor. to a runconductor terminal connectors:A connectorthatjoins a conductor(s) to an electricaldevice.

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ANSfCl19.4-20U

2

ApplicableStandards

Thisstandardis intendedto be usedin conjunction with,butnot limitedto, the followingstandardsin their latestedition:

\t

ASTM81-01,HardDrawnCopperWre ASTM 82-00, Mediurn-Har&Draw n CopperWre ASTM 88-99, concentric-Lay-strandedcopper conductor,Hard, MediurwHad, or soft AsrM 8228-02,c oncentric-Lay-stranded cop per-clad steelcondu ctors ASTM 8,22942,Concentic-Lay-Stranded Copperand CoppenCtadSteetCompositeConductors ASTM8230/B230M-99, Aluminum13s0-H19wre for Electricatpurposes ASTM 8'23118231M-99, Concentric-Lay-Stranded (AAC)Atuminum1350Conductors ASTMB,2321B,232M-01e1, Concentric-Lay-Stranded AluminumConductors, Coated,Steel-Reinforced (ACSR) ASTM8341/8341M-OO, AluminumCoated(Aluminized)Stee/CoreWre for AtuminumConductors,Steel Reinforced(ACSR/AZ) ASTM 8396-00,Aluminum-Alloy500*H19 Wre for Etectricatpurposes ASTM 8397-85(1999),Concentric-Lay-Stranded Aluminur*Attoy500*H19 Conductors ASTM8398/8398M-99, AluminurwAlloy6201-781wre for Etectricatpurwses ASTM8399/B399M-99, Concentric-Lay-Stranded Atuminum-Atloy 6201-781Conductors ASTM8400-01, CompactRoundConcentic-Lay-Stranded 1350AluminumConductors ASTM 8401-99,CompactRoundConcentric-Lay-Stranded AtuminumConductors,SteelReinforced (ACSR/COMP) ASTM841U98, Har&DravtnAluminum-Clad SteetWre ASTM8416-98, concentric-Lay-stranded Aluminum-ctad steet conductors ASTM8498/8498M-98,Zinc-Coated(Galvanized)SteetCoreWre for AtuminumConductors. Sfee/ Reinforced(ACSR) ASTM8500/8500M'98,Metalliccoated StrandedSfee/CoreforAluminumConductors.Steet-Reinforced (ACSR) ASTMB5O2-02, Aluminum-CladSteelCoreWre for AluminumConductors, AluminumCtad.SteelReinforced ASTM 85241B,524M-99, Concentic-Lay-Stranded Atuminum Conductors,AluminumAttoy Reinforced (ACARand 1350/6201) ASTM8549-00,Concentric-Lay-stranded AluminumConductors, Aluminurn-Ctad SteetReinforced (ACSR/AW

2

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ANSfC119.+200/'

V\7

ASTM 8606-98,High-StrengthZinc-Coated(Galvanized)SteelCorc Wre for Aluminumand AluminurnAlloyConductors,steelReinforced ASTM8609/8609M-99, Aluminum1350RoundWre,Annealedand lntermediateTempers,for Electical Purposes ASTM 8701/8701M40,Concentric-Lay-Stranded Self-Damping AluminumConductors,SteelReinforced (ACSR/SD) ASTM 8778-97,ShapedWre CompactConcentic-lay-stranded AluminumConductors(AAC/W ASTM8779-96,ShapedWre CompactConcentric-lay-stranded AluminumConductors,Steel-reinforced (ACSR/TW) ASTME4-01,Practicesfor Force Veificationof TestingMachines

3

Test conditions

3.1

General

Connectorsshallbe installedand testedfor current-carrying and mechanicalperformancein accordance withthe conditions notedin clauses5 through7.

3.2 , \z

Gurrentcycle tests

Testsshallbe conductedin accordance withclause6 and shallbe of the durationlistedin Table1, depending on the cunentclassof the connector andthe choiceof testmethod(CurrentCycleTesi (CCT) or CunentCycleSubmersion Test(CCST)). Tablel -Testduration ConnectorClass

Numberof Test Cyclesfor: CGT Method

CCST Method

ExtraHeavyduty (ClassAA)

500

NA

Heavyduty(ClassA)

500

100

Mediumduty(ClassB)

250

75

Lightduty(ClassC)

125

50

3.3

Mechanicaltests

a

Testsof tensilestrengthof the connection,reusabilityof the connector,and effecton the strengthof the iniine conductorshallbe conductedin accordance withclause7 for the strengthclassas listedbelow: Class1 - Fulltension Class2 - Partialtension Class3 - Minimumtension

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ANS|C119.+2W

4

Performance

4.1

General

performance requirements in 4.2 through4.7,wheninstalled Connectors shallconformto the appropriate and testedin accordancewith the methodsspecifiedin clauses5 through7.

4.2

Resistance

The resistanceof the connectiontestedin accordancewith clause6 shallbe stable. Stabilityis achieved for measurement enor,doesnotvaryby morethan if any resistance measurement, indudingallowance at specifiedintervalsduringthe courseof the test. tSolofromthe averageof all the measurements 4.2.1 CCTresistance The resistanceof the connectiontestedby the CurrentCycleTest methodin accordancewith clause6 shallbe stablebetweenthe twenty-fifihcycleand the completionof the numberof currentcyclesrequired in 3.2for the connector classtested. 4.2.2 CCSTresistance Testmethodin accordance testedby the CunentCycleSubmersion The resistance of the connection with clause6 shallbe stablebetweenthe tenthcycleand the completionof the numberof currentcycles requiredin 3.2for the connector classbeingtested.

4.3

Temperature

The temperatureof the connectortestedin accordancewith clause6 shallnot exceedthe temperatureof the controlconductor.The temperaturedifferencebetweenthe controlconductorand the connectorshall difference betweenthe controlconductorandthe be stable.Stabilityis achievedif anytemperature for measurement error,is notmorethan 10"Cbelowthe averageof all connector, includingallowance temperature in thisinterval. differences 4.3.1 GCTtemperature The temperatureof the connectortestedby the CurrentCycleTest methodshallbe stablebetweenthe twenty-fifthcycleand the completionof the numberof cunentcyclesrequiredin 3.2 for the connector classbeingtested. 4.3.2 CCSTtemperature The temperatureof the connectortestedby the CunentCycleSubmersionTest methodshallbe stable of the numberof currentcyclesrequiredin 3.2for the betweenthetenthcycleandthe completion conductorclassbeingtested.

4.4

Tensilestrength and rated conductor strength

4.4.1 Tensilestrength with7.3.4.1shallbe equalto or greaterthan Thetensilestrengthof the connections testedin accordance the valueslistedin 4.4.3.

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ANS|C119.+200/.

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4.4.2

Ratedconductorstrength,as usedin this standard,shallbe determinedin accordancewith the applicable ASTMstandardlistedin clause2, or as furnishedby the conductormanufacturer for nonstandard conductors. 4.4.3

t

Ratedconductor strength

Classesof tensile strength

4.4.3.1Class1, fulltension The tensilestrengthshallbe equalto or greaterthan 95%of the ratedconductorstrengthof the weakerof the conductors beingjoined.A conductorshallbe considered as a failurewhenat leastonestrand breaks. Forconnectorsof the typethat do not haveseparategrippingmeansfor the differentmetalsof compositeconductorsor that use nonferrousmeanson fenousconductorsor cpres,they shallfirst be testedin accordance with7.3.3.1without slippageor breakage. 4.4.3.2Glass2, partialtension Thetensilestrengthshallbe equalto or greaterthan40%of the ratedconductorstrengthof the weakerof the conductors beingjoined. 4.4.3.3Glass3, minimumtension The tensilestrengthshall be equalto or greaterthan 5% of the ratedconductorstrengthof the weakerof the conductors beingjoinedbut notlessthanthevaluesin Table2. Table2-Tensileload \y

Wire Size (AWG}

Pullout Gopper lbr

16

30 50 70 80 90 100

180

133* 222" 311* 356* 400* 445* 623* 712* 801*

200

890*

14

12 10 I

6 4 3 2 1

N*

140

160

Aluminum

rb

N*

15 25 35 40

67* 111* 156* 178* 200*

45

50 70 80 90 100

222* 311* 356* 400* 445*

ACSR

th

N*

100 100 150 150 200 200

4/.5* 667* 667* 890* 890'

445'

* For referenceonly

fr' 4.5 \ .l

Reusableconnectors

Uponcompletion of all tests,a connector thatis designated by the manufacturer to be reusableshallstill functionas originallydesigned.Reusablemeansthatthe connectormaybe removedfromserviceand installedagain.Priorto reuse,any reusableconnectorshallbe reconditioned in accordancewith manufacture/sinstructions.

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ANSfC119.+20U

4.6

Tap connector

A tap connectionsatisfiesthe mechanicalrequirementif, afterperformingthe conductordamagetest in 7.5,the run conductorretainsat least90%of its ratedbreakingstrength. as statedin 4.4.3.3. shallmeetthe tensilerequirement ln a separatetest,tap wireconnection(s) a

4.7

Torque requirements

torqueor, in the absenceof tightening of the manufacture/s shallwithstand12Oo/o A boftedconnec{or part. is definedas a crack, Damage component damage to any Table 3 without in those shown such, detectedby visualmeans(see7.4). Table3 - Tighteningtorquer'2

Aluminum Fastener

Threaded Fastener Size

Galvanized Steel,Stainless Steel or Silicon Bronze Fastener lb in.

Nm*

180

20.3

19.0

240

27.1

2U

23.0

288

32.5

11.1

240

27.1

360

40.6

1t2

12.7

300

33.9

480

54.2

9/16

14.3

384

43.4

576

65.0

5/8

15.9

480

54.2

660

74.5

In.

mm*

5/16

7.9

3/E

9.5

168

13t32

10.3

7t16

lb in.

Nm*

'For referenceonly. tForuseonlyin absenceof the manufac{ure/s recommendation. 2Connectors to be installedas suppliedby the manufacturer.

5

Test Procedures,General

5.1

Test connectors

i

5.1.1 Description compoundshallbe includedin andinhibiting conductors, of the testconnectors, A completedescription the test report(seeclause8).

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5.1.2 Familysampleset

1

(groupof connectors usingsimilardesigncriteria),a minimumof three To qualiffa familyof connectors connectorof the shallbetested.\Mtenonlyonesmaller-size sizes(largest,smallest,and intermediate) is not required. previously parameter family, additionaltesting tested is added to a samedesign

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ANS|Cl19.+20A4

5,2 \/

Test conductors

The conductorsusedin thesetestsshallbe unusedbareconductors.Flat barsto whichterminal connectorsare boltedshallbe consideredconductors.The flat-barconductorshallbe the nearestsize that can be boltedto the terminaland havea cunentcapacityclosestto that of the maximumconductor accommodated.

5.3

Test assemblymethods

5.3.1 Installationdetails All installation details,includingmethodsandtools,notspecifically definedor requiredin clauses5 through7, shallbe completely desoibedin thetestreport. 5.3.2 Conductor preparationfor electrical tests The outersurfaceof the conductors in the contactareashallbe mechanically cleanedusinga wirebrush untilthe entirecontactareaof the conductoris clean. 5.3.3 Conductorpreparationfor mechanicaltests The portionof the conductor that is to be insertedintothe connectorshallbe wipedwitha particle-free jelly,unlessthe connectoris usedwithan inhibitingcompound. clothcoatedwithpetroleum 5.3.4 Connectorpreparation Connectorsshallbe preparedin accordancewiththe manufacturefsrecommendations. \-

5.3.5 Connectorinstallation The methodsandtoolsusedto installtheconnectorshallbe in accordance withthe manufacture/s recommendations. lnstallation shalltakeplacein an ambientenvironment between15"C(59"F)and 35'C (95' F).\Mtenclampingfastenersare used,theyshallbe tightenedin accordance withthe manufacturefs recommendations. In the absenceof a recommended torque,the valuesspecifiedin Table3 shallbe used.

6

Current GycleTest Procedures

6.1

General

Cunentcycletestsshallbe conductedon connectorsassembledin seriesin a loopin accordancewith cfauses5 and6.2through6.'12.2.An accelerated currentcycletestmethod,referredto as the cunent cyclesubmersiontest (CCST) is offeredas an altematetest method usedprimarilyto quicklyassess connectorperformance.The cunentcycletest (CCT)remainsthe preferredtest methodrecommended for the qualificationof a connec{or. NOTE-The CCSTmethoddiffersftomthe traditionalcurrentcycletest (CCT)in thattestconnectors are rapidlycooledby immersionin chilleduraterat the beginningof the "cunent€FF"cycle. Comparative testinghasdemonstrated thatthe CCST methodwill provideessentiallythe sameperformancetest resultsas the traditionalcurrentcycletest (CCT)in fanriertest cycles.

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ANS|C119.+200/.

6.2

Test assembly

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6.2.1 Conductors shallbe selectedto maximizecunentthroughthe connector.lf the combinations 6.2.1.1Conductor conductors, andaluminum-to-copper betweenaluminum-to-aluminum for use connectoris recommended combinations. on both tested it shallbe wfierethe conductorselectedlimitsthe cunent,the otherconductor 6.2.1.2ForClassAA connectors cunentrating. shouldbe sizedas closeto butnot lessthanthe limitingconduc{or NOTE-f n both 6.2..1.1and6.2.1.2 additionalconducior combinationsand cunent values may also be used if agreed to by both the manufac{urerand user.

6.2.2 Connectors Fourconnectorsof the samesize andtype are requiredfor eachcombinationof conductors,as (pador tang-to-tang to flat barconductors maybe connected in 6.2.1.Terminalconnectors determined to'pad).

6.3

Equalizers

andto preventthe influenceof one planesfor resistance measurements To provideequipotential on eachsideof eachconnector shallbe installedin strandedconductor on another,equalizers connec{or (pad-to-pad). tang-to-tang are tested connectors wheretwoterminal in the cunentcycleloop,'except permanent contact that ensures equalizer form of Any are not requiredon solidconductors. Equalizers used. may be duration test for the strands amongall the conductor 6.3.{

Weldedequalizerc

are madeftom for aluminumconductors.Weldedequalizers A weldedequalizeris recommended aluminum 6.3.2 Compressionsleeveequalizerc \Mrenthe connectorsto be testedare identical,a continuouspieceof conductormay be usedbetween sleeveis employedas an equalizerwith withan equalizerin the center.lf a compression the connec{ors, the conductorin the contactareaof the equalizershouldbe preparedas in 5'3.1 aluminumconduc{ors, and5.3.2.

6.4

Gonductorlengths

The exposedlengthof strandedconductorbetweenthe connectorand the equalizer,or betweenthe withTable4. lf a flat bus in the cunentcycleloop,shallbe in accordance of solidconduc{ors connectors in bar is usedbetweenterminalconnectors,its lengthshallbe twicethat shown table4 for the stranded conductorsizebeingusedin theterminal,or the samelengthof the solidconductorbeingusedin the terminal.Theconductorlengthin Table4 doesnotincludethe lengthwithinthe connectoror equalizer. endshallprojectll2inch (12'7 mm)beyond permits,the conductor ln addition,whereconnec{oidesign the currentcycleloopshallbe joinedto the of end at each groove. Thl equalizers the connectorcontact powersouroewith additionallengthsof the test conductorto be not lessthanthe lengthsspecifiedin Table4.

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ANS|C119.+20U

Table 4 - Gonductorlengths for current cycle tests \-'

ExposedLength Aluminumor AluminumComposite

Gopperor CoooerComoosite Solid

Stranded tn.

mm*

tn.

mm*

Up through4/0 AWG

Up through2/0A\ re

12

305

24

610

Over4/0 A\A/G through795 kcmil

Over 2/0 AWG through500 kcmil

24

610

48

1219

Over795 kcmil

Over500 kcmil

36

914

72

1829

6.5

Gontrol conductor

A controlconduc{or,for determiningtest current,shallbe installedin the cunentcycleloop (betweentwo equalizers for strandedconduc{ors). Thecontrolconductorshallbe the sametypeand sizeas the conductorin the cunentcycleloopthatwouldbe at the highesttemperature.lts lengthshallbe twicethat givenin Table4. ForClassAA,whenthe controlconductoris copper,see6.5.2.

v

6.5.1 Equivalentaluminum/copperconductors by selectingfromTable At the manufac{ure/s option,the sizeof the controlconductormaybe determined aluminum/copper 5 the conductorin the cunentcycleloopthathasthe leastcunentfor equivalent conductors. 6.5.2 Multiplecontrol conductors 6.5.2.1 lf the testloopincludesdifferentconductors, and a questionarisesas to whichconductorcauses rise,a controlconductorof eachtypeis required.Thetestcunentshallcause the highesttemperature of 6.8. the highertemperature risein oneof the controlconductors to meetthe requirements 6.5.2.2ForClassAA, if the conductor for determining testcunentis copper,thena secondcontrol stabili$.The secondcontrolcable conductorof aluminumshallbe includedfor the purposeof evaluating shallbe of the closestampacityandchosenbasedon the valuesshownin Table5. However,the copper controlconductorshallbe usedfor establishing the currentwithinthefirst25 cycles.

6.6

Loop configurationand location

6.6.1 CCTmethod The cunentcycleloop may be of any shapeprovidedthe connectorsand the controlconductorare plane,withat leastan 8 in. (203mm)separation betweenconductors and installedin the samehorizontal locatedat least1 ft (305mm)fromanywallandat least2 ft (610mm)ftomthefloorandthe ceiling. NOTE-This assu.esthat the contsolconductorand the @nnec{orsbeginthe nextcunent-ONperiodat the sametemperature.

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ANS|C119.+2004

6.6.2

CCSTmethod

planeas the testconnectors.Duringthe shallbe installedon the samehorizontal The controlconduc{or cunent-ONperiod,no partof the circuitshallbe lessthan8 in. (200mm)abovethe surfaceof the chilled water. At the beginningof the cunent-OFFperiod,the connectorsand the controlconductorshallbe to a minimumof 4 in. (100mm)belowthewatersurface. submerged NOTE-This assuresthatthe controlconductorandthe @nnectorsbeginthe nex cunent-ONperiodat the sametemperature.

Table5 - Suggestedinitialtest currentto raise control conductortemperature100"C Copper or CopperComposite

Aluminumor AluminumComposite Conductor (AwG)

Current (Amperes)

Conductor (AwG)

Current (Amperes)

6

90

8

95

4

125

6

130

2

170

4

180

1

200

2

245

1n

230

1to

340

2n

270

ao

400

3 )

320

3/0

470

4n

380

4to

550

(kcmil)

(kcmil) 266.8

450

2n

615

336.4

525

300

700

397.5

590

350

780

477

670

400

850

7fi

500

990

636

820

750

1300

795

955

1mo

1565

954

1085

a56.5

10

1033.5

1150

1113

1220

1192

1275

1272

't350

1351.5

1390

1431

1450

1590

1560

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ANSIC119.+2004

6.7

Ambientconditions

\' Cunentcycletestsshallbe conductedin a spacefree fromforcedair cunentsor radiatedheatstriking (directlyor indirectly) period.Theambienttemperature any portionof the testloopduringthe current-ON shallbe held between15"Cand 35'C. I

6.8

Test current

Thecunentvaluesin Table5 arethe suggestedinitialtestamperesfor thisstandardfor ClassA, B, and C and havebeenselectedto simplifycurrentselectionin orderto achievethe requiredtemperaturerise in the controlconductor.Forconductors largerthanthoseshownin Table5, the currentis determined by reachinga stabletemperature.Thesecunentsare not intendedto suggestcurrentvaluesfor use in actualservice.ClassAA test currentsare establishedby obtainingthe propertemperaturerise. 6.8.1 CCT temperatureconditions The cunentcycletest currentshallbe adjustedduringthe cunent-ONperiodof the first twen$-fivecycles to resultin a steady-state riseon thecontrolconductorof 100"Cto 105"Coverambient temperature temperature for ClassA, B, andC. The ClassAA risewill be 175"Cto 180'Coverambienttemperature. Thiscunentshallthenbe usedduringthe remainder of the testcunent-ONperiods,regardless of the temperatureof the controlconductor. 6.8.2 CCSTtemperatureconditions

^ \,

The cunentcyclesubmersion periodof the first five testcurrentshallbe adjustedduringthe current-ON cydes to resultin a steady-statetemperatureriseon the controlconductorof 100'C to 105'C over ambienttemperature.Thiscunentshallthenbe usedduringthe remainder of thetestcurrent-ON periods,regardlessof the temperatureof the controlconductor. 6.8.3 CGTmethodelevatedtemperaturecurrentstabillzation The cunentcycletest currentshallbe increasedfromthat shownin Table5 to achievethe appropriate elevatedtemperaturewithinthe firsttwenty-fivecycles. 6.8.4 CCSTmethod elevatedtemperaturecurrent stabilization The cunentcyclesubmersiontest cunentshallbe increasedfromthat shownin Table5 to achievethe appropriateelevatedtemperaturewithinthe firstfive cydes.

6.9

Current cycle period

period.Thetimerequiredto make Eachtestcycleshallconsistof a cunent-ONanda current-OFF resistanceand temperaturemeasurements is not considereda partof the cunent-ONor cunent-OFFtime periods. ?

'

6.9.1 Gurrentcycle0N period

I

periodshallbe as listedin Table6, depending The lengthof the current-ON on the sizeof the control conductor.Forconductors largerthanthoseshownin Table6, the current-ON timeis determined by reachingand maintaining thermalstabilityin the connector.Thermalstabilityis definedas not morethan a variationof 2C betweenanytwo of threereadingstakenat notlessthan 10 minintervals.

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11

ANS|C119.+200/

Table 6 - Current cycle periods for control conductorc

v

AluminumorAluminum Composite(kcmil)

Copper or Copper Gomposite

Current0N Period (Hour)

Up through336.4

Up through#4/0 A\ rG

1.0

Over336.4through795

Over#4/OAWGthrough500 kcmil

1.5

Over795through1590

Over500 kcmilthrough1000 kcmil

2.O

6.9.2 CCTcurrentcycleOFF period air. The testedby the CurrentCycleTest(CCT)methodshallcoolin ambienttemperature Connectors initially be the same shall method CCT period the tested by for connectors time lengthof the cunent-OFF first twenty-five after the air cooling forced reduced by period. may be The length time as the cunent-ON cycles. \Afiththe manufacture/sconcunence,forcedair coolingmay be initiatedduringthe current-OFF periodafierthe first cycle. The time lengthfor the reducedcunent-OFFperiodshallbe establishedby to reachambienttemperature. adding5 minto thetimerequiredfor thefourconnectors 6.9.3 CCSTcurrentcycle€FF period Test(CCST)methodshallbe immersedin still, testedby the CunentCycleSubmersion Connectors shall + chilledwater(5.C 4"C)within30 secondsof the startof the cunent-OFFperiod.Theconnectors is connector of the temperature after the 15 min for minimum of remainimmersedin the chilledwater a before they water from the removed be shall The the water. connectors of reducedto the temperature are energizedat the beginningof the nextcurrent-ONcycle.

6.10 Measurements on the choice to Table7, depending measurements shallbe madeaccording Resistance andtemperature 7, the in Table specified those exceeds datums measurement number of \Mren the test method. of for ClassA, B, and C nearesteachspecifiedcycleshallbe usedto evaluateperformance measurements shallbe takena connectors.For ClassAA connectors,resistanceandtemperaturemeasurements minimumof onceeverytwentycycles.

i

1

12

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ANSfCl19.+2004

Table 7 - Resistanceand temperaturemeasurementinteryals* \/

Current Cycle Test Method(CCT) (Cycles)

CurrentCycleSubmersion Test Method(CCST) (Gycles)

25-30

5-7

45-55

8- 12

70-80

1 8- 2 2

95 - 105

28-32

120- 130

38- 42

160- 170

4a-52

2@-2'tO

58-62

245-255

68-72

320 - 330

78-82

400- 410

88-92

495 - 505 ' Doesnot applyto ClassAA Connec{ors.

98 - 102

6.10.1 Resistancemeasurements \,

periodwithall connectors Resistance measurements shallbe madeat the end of a current-OFF thermally stabilized at the roomambienttemperature.Thermalstabilityis definedas not morethana variationof 2"C betweenany two of threereadingstakenat not lessthan 10 min intervals.Resistance mea$Irementsshallbe madeacrosseachconnector,betweenpotentialpointslocatedeitheron the equalizers a maximumof one conductor diameterfromthe edgeadjacentto the conductoror at the midpointof a solidconductor.A lowmagnitude directcunentnotto exceed12Ashallbe usedfor these measurements. Ambienttemperature shallbe measuredwithin2 ft (610mm)of thetestloopat a locationthat minimizesthe effectof thermalconvection.The ambienttemperatureshallbe recordedat the time of eachset of resistancemeasurements.The resistanceof eachconnectorassemblyshallbe conectedfromthe measuredtemperatureto 20'C. The conec{edresistancevaluesshall be usedto evaluatethe performanceof the connectors. NOTE-The resistance valuesobtainedshallbe conectedto 20'C withthefolloadng formula:

R z o = R ,l 1 1+ s ( T m - 2 0 ) l \Mtere R. is the measuredresistance,T, is the temperature('C) of the connectorand cris the resistance variationcoefficientwith the temperature.This coefficientcan be takenequalto: {

I

cr= 4 X 1O{/"Cfor copperandACSR

I

cr= 3.6X 1O€/'Cfor aluminum

I

6.10.2 Temperaturemeasurements

v

Temperaturemeasurements of the connec{ors,controlconductors,and ambientair shallbe madeat the end of the specifiedcunent-ONcycle,immediatelybeforethe currentis tumedoff. The temperatures

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13

ANSfC119.+200/that havebeenpermanentlyinstalledfor the cunentcycle shallbe measuredby meansof thermocouples shallbe installedin the cunentpathof eachconnectorat a pointwhere tests. At leastonethermocouple shallbe installedat the midpointof the control is anticipated.Onethermocouple the highesttemperature conductor.

V

6.11 Maximumnumber of current cycles The numberof cyclesspecifiedin 3.2,Table1, to completethe testmaybe extendedto permittakingthe duringnormalworkinghours. finalmeasurements

6.12 Evaluationinterval as specifiedin 4.2 and4.3,shallbe madeon the basisof The evaluation of the connectorperformance, resistanceand temperaturemeasurements. 6.12.1 Evaluationby the GGTmethod with6.10shallbe usedto evaluate measurements takenin accordance The resistance andtemperature connectorstestedby the CurrentCycleTest (CCT)method. 6.12.2 Evaluationby the CCSTmethod withsection6.10shallbe usedto measurements taken in accordance The resistance andtemperature evaluateconnectorstestedby the CunentCycleSubmersionTest (CCST)method.

7

Mechanicaltestprocedures

7.1

General

withclause5 and7.2through7.5. Mechanicaltests shallbe conductedin accordance

7.2

Test connectors

to eachmechanical shallbe subjected combination 7.2.1 Threesamplesof eachconnector-conductor testdescribedin 7.3.7.4. and7.5. 7.2.2 Bothdeadendsandsplicesshallbe testedunlessit can be shownthatthe samedesign pararnetersand materialsare usedfor bothdevices. lf onlyone deviceis tested,it shallbe the deadend.

7.3

Pullouttest

for whichthe combinations on thefollowingtwo conductor 7.3.1 Pulloutstrengthtestsshallbe performed connectoris designed: (1) (2)

and The highestratedtensilestrengthconductor The smallestdiameterconductorof the highestratedtensilestrength.

maybe requiredandthe connectormanufacturer specialjoiningtechniques NOTE-lf the conduc{or corehas beengrease-filled, shouldbe consulted.

7.3.2 lt the connectorscan be usedon differentconstructionand/ormaterials,the test shallbe run on eachconductorcategorysuchas ACSR,AAC,AAC/TW,etc.

\t 14

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ANS|C119.+2004. 7.3.3 Tensilestrength \,

The samesamplesshallbe usedfor boththe sustainedloadtestingand maximumloadtesting. Relaxationof tensionbetweentestsis permissible. 7.3.3.1Sustainedload installedgrippingmeans of the typethatdo not haveseparately connectors 7.3.3.1.1Class1, full-tension for the differentmetalsof compositeconductors,or whichuse nonferrousmeanson ferrousconductorsor in assemblies as describedin 7.3.3.1.2.A constant the connectors cores,shallfirstbe testedby installing shallbe as determinedin4.4.2, tensileloadequalto77o/ot 5oloof the ratedstrengthof the conductor, for a minimumof 168hours. on the assemblies appliedand maintained 7.3.3.1.2The lengthof the exposedconductorin the testassemblybetweeneachgrippingmeansand eachconneclorshallbe at least12ft (3.66meters).The grippingmeansmaybe any devicecapableof securelygrippingall strandswithoutslippagefor the durationof the test. lf anotherconnectorof the same type as the connectorbeingtestedis used,it mayalso be consideredas a test connector. 7.3.1 Maximumload 7.3.4.1\Mrenconducting thetensilestrengthtest,careshallbe takento ensurethatall strandsof the conductorare loadedsimultaneously. speednotexceeding114in. per minperft (20.8mm per 7.3.4.2The loadshallbe appliedat a cross-head min per m) of the total lengthof the exposedconductorbetweenjaws. 7.3.4.3The lengthof the exposedconductorbetweeneachgrippingmeansandeachconnectorshallnot be lessthanthatgivenin Table8.

\-

as the maximumloadthatcan be applied.Thisload 7.g.4.4Thetensilestrengthshallbe determined for Class1 connectorsand 5olofor Class2 and3 connectorswith shallbe measuredto an accuracyol 1o/o accordingto ASTME4. The modeof failureshallbe recorded. instruments calibrated 7.3.4.5Minimumvaluesindicatedin 4.4.3are required.

7.4

Torque strength test

7.4.1 The torquestrengthof the boltedconnectorshallbe measuredusingconductorsof the largest for whichthe connectoris designed(see4.7). and smallestdiameters devicethatis accuratewithin2%. torquevaluesshallbe measuredusinga measuring 7.1.2 Tightening torqueat 7.4.3 Thetorquestrengthof a boltedconnectoris the thresholdvalueof the bolttightening occursthatimpairsits proper whichruptureor permanent distortionof anyconnectorcomponent was designed. for whichthe connector functioning on anyof the conductor combinations

7.5

Conductordamagetest

and on maximurn-run shallbe performed 7.5,1 The conductor damagetestfor the tap connector of eachtypefor whichthe connectoris designed.In all tests,the maximumminimunrrunconductors diametertap conductorof the hardesttemperfor whichthe connectoris designedshallbe used. whoselengthbetweengrippingmeansis as shallbe installedon a runconductor 7.5.2 A tap connector of its ratedstrengthas determinedin specifiedas Class1 in Table8, and is undera tensileloadof 20o/o \-.

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15

ANS|C119.+2W The conductorshallthenbe of the loadshallnotoccurduringconnectorinstallation. 4.4.2. Relaxation point. breaking stressedto the Table 8 - Length of exposedconductor Length

Description

Connector Class

lnches

Meters

Class1 (a)

Intendedfor singlemetalorsinglealloy with 19 strandsor less. conductors

24

0.61

(b)

Intendedfor singlemetalor singlealloy withmorethan 19 strands conductors

1M*

3,66*

(c)

Intendedfor multiplemetalormultiplealloy conductors

144'

3.66*

Class2

24

0.61

Class3

10

o.25

*Exception: For conductors4/OAI lt3 and smaller, the length of the exposed conductor may be shortenedtrom 144 in. (3.66 m) to 24 in. (0.61 m), if proceduresensure simultianeousloading of all strands.

8

Test report

to the or nonconformance datato supportconformance Thetestreportshallincludethe necessary of thisstandard,andalsothe following: requirements Dateof test Descriptionof test assemblies Descriptionof connectorsand inhibitingcompoundbeforetestingto ensuretraceability Descriptionof conduc{ors,includingratedconductorstrengths Descriptionof connectorinstallationprocedure Cunentcycleamperage Descriptionof the conditionof connectorsafiertesting Electrical: ClassAA,A, B, C Class1,2, 3 Mechanical: Method:CCT,CCST Narneand addressof the test facilityand the namesof the techniciansperformingthe test of the testincludingthe mountingmethod(drilledor surfacemounted)of All optionsusedin performance photographs (diagrams of the testsetupare desirable) or the thermocouples Otherpertinentinformation,suchas installationdetailsnot specificallydefinedor requiredin this standard Certification(if required)

16

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