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AI{SI CTT9.4-2004
Ameri catrNational Stand ard for Electric Connectofs_
Connectors for Use Between Alumi n um -t o-Alurni num or Aluminum-to-Copper Conductors

ErctEnric oocurtlll

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trlt lt lm$sbi 0t ilEmA tG..tn ttl Urar ft*t

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ANS! C119.4-2004

American National Standard ForElectric ConnectorsGonnectors UseBetween for Aluminum-to-Aluminum or Aluminum-to-Gopper Gonductors

Secretariat:

NationalElectricalManufacturersAssociation
Approved December 2004 30,

American NationalStandardsInstitute,Inc.

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ANSfC119.+2004

Contents
Page

Foreword

@Copyright 2005by the National Electrical Manuf;acturers Association

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ANS|C119.+2M preparation............. 5.3.4 Connector 5.3.5 Conneclor installation Cunent cycfe procedures test 6.1 General 6.2.1 Conductors 6.2.2 Connec'tors 6.3 Equalizers.. 6.3.1 Welded equalizers.. 6.3.2 Compression sleeve equalizers 6.4 Conductor lengths 6.5 Control conductor 6.5.1 Equivalent aluminum/copper conductors 6.5.2 Multiple control conductors. 6.6 Loopconfiguration location and 6.6.1 CCTmethod 6.6.2CCST ethod....... m 6.7 Ambient conditions 6.8 Testcunent 6.8.1 CCTtemperature conditions 6.8.2 CCST temperature conditions..............:...... 6.8.3 CCTmethod elevated temperature current stabilization 6.8.4 CCSTmethod elevated temperature cunent stabilization 6.9 Cunent cyleperiod period......... 6.9.1 Cunent cycle-ON period 6.9.2 CCTcurrent cycle-OFF period......... 6.9.3 CCST cunent cycle.OFF 6.10 Measurements.... 6.10.1 Resistance measurements.............. 6.10.2 Temperature measurements.............. 6.1{ Maximum number cunent of cycles 6 . 1 2 E v a l u a t i on t e r v a | . . . . . . . . . . . . . . . . . . i n 6.12.1 Evaluation theCCTmethod by ................ 6.12.2 Evaluation theCCSTmethod by procedures............. Mechanicaltest 7.1 General 7,2 Test onnectors............. c .................7 ............7 ....................7 .......7 .........8 .........I ....................8 ...............8 ...............8 .........8 ..........I ....................9 ......................9 ........9 .......9 ...............10 ......11 .................. 11 .................. 11 .............. 11 ..............11 ...........'11 ......11 ................ 11 ...............12 .......................12 .........12 .....13 ..................... 13 ..................14 ........14 ...............14 ..........14 ........14 .....14 .................14

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ANS|C119.+2004 7 . 3 P u l l o ue s t . . . . . . . . . . . . . tt 7.4 Torque strength test............ 7.5 Conductor damage ......... .. test .. Testreport ......14 ...........15 ..... 15 ..........16

Tables
1 2 3 4 5 6 7 8 Testduration Tensile load Tightening torque Conductor lengths cunent for cycle tests.. ........3 ..........5 .....................6 g .....................

Suggested initial cunent raise test to control conductor temperature 100.C....................... 1o Cunent cycleperiods control for conductors. ..............12 Resistance temperature and measurement intervals Length exposed of conductor .................... 13 ................... 16

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ANS|C119.+2004

FOfewOfd fihis Foraaord notpartofAmerican is National Standard C11g.4-2OO4.l This standard describes cunentcycleand mechanical performance tests usedto establish characteristics of connectors usedto join aluminum-to-aluminum or aluminumto-copper overhead bare conductors. This revision includes alternate, an accelerated currentcycletest method, henceforth refenedto as the currentcyclesubmersion (CCST).The CCSTmethoddiffersfromthe traditional test cunentcycletest (CCT)in thattestconductors rapidly are cooled immersion chilled by in waterat the beginning the of 'cunent-OFFcycleand requires fewertotalcurrent-ON cunent-OFF and cycles.Comparative testinghas demonstrated the CCSTmethodwill provide that essentially sameperformance resultsas the the test traditional cunentcycletest (CCT)in fewertest cycles.The currentcycletest remains prefened the test methodrecommended qualification a connector. for of Thisrevision includes additionalcunent an cycletestmethod (CCT)utilizing elevated temperature testing for an extraheavyduty connector category, ClassAA. The intentof elevated temperature Class test in AA testingis to providea betterperforming connector. Thisstandard initially was developed underthe direction the Transmission Distribution of and Committee of the Edison (EEl). Tentative Electric Institute performance-type specifications electrical for characteristics issued jointreport were in formin 1958by a steering committee EEIand an advisory of committee manufac{urers the aluminum of on project conductor (EEl Pub.No.59-70, research Tentative Specifications Conneclors Aluminum for for Conductors). gainedfromextensive usefurtherconfirmed performance Experience trial the criteriaand test conditions of the tentative specifications ledto the development Standard and of TDJ 162in October 1962by a joint committee EEIandthe National of Eleclrical Manufacturers (NEMA).TDJ 162was Association subsequently superseded thisdocument. by The Subcommiftee Overhead on Connectors theAccredited of Standards Committee Connectors on for Electric Utili$applications, C119,in itsconstant review the publication, of continues seekouttheviews to of responsible usersthat will contribute the development befterstandards. to of Suggestions improvement thisstandard be welcome.Theyshouldbe sentto the National for of will Electrical Manufacturers Association, 1300North17thStreet, Suite1847,Rosslyn, Virginia 22209. This standard was processed approved submittal ANSI by the Accredited and for to Standards Committee Connectors Electrical on for Utility Applications, C119. Committee approval thisstandard of doesnotnecessarily implythatall committee members votedfor its approval. the timeit approved At this standard, C119Committee thefollowing the had members: DouglasHarms,Chairpetson RonaldLai,Vice Ghairperson VinceBaclawski, Secretary Organizations Represenfed; Aluminum Association EdisonElectric nstitute I Nameof Representative: Jean-Marie Asselin WanenHadley Douglas Harms JamesHanis HarryHayes CurtSchultz GeraldWasielewski

VI

@Copyright 2005by the National Electrical Manufac{urers Association

ANS|C119.+2004 DavidWest

NationalElectricEnergy Testing,Research Application & Center NationalElectrical Manufacturers Association

Thomas Champion BethBruns DavidDembowski Ronald Lai FrankMuench GregNienaber FrankStepniak CarlTamm CarlTaylor David Thompson JamesZahnen Trung Hiu JeffreyNelson JakeKillinger Stanley Hodgin

(RUS) RuralUtilities Service Tennessee ValleyAuthority Underwriters Laboratories, Incorporated Other

The C119.4 Subcommittee Connectors UseBetween Aluminum-to-Aluminum on for or Aluminum-toCopper had Conductors, whichdeveloped revisions thisstandard, thefollowing the of members the at timeof approval:

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

@Copyright 2005by the National Electrical Manuf;acturers Association

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AMERICAN NATIONAL STANDARD

\,

ANS| C119.4-2004

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Gonnectors for Use BetweenAl umi num-to-Alumi num or Aluminum-toopper Bare OverheadGonductors 1 1.1 Scopeand Purpose Scope

Thisstandard covers connectors usedfor making electrical connections between aluminum-to-aluminum or aluminurn-to-copper conduc{ors usedon distribution transmission for electric lines and utility. Thisstandard establishes electrical mechanical requirements electrical the and This test for connectors. is standard not intended recommend to operating conditions temperatures. or

1.2

Purpose

The purpose thisstandard to givereasonable of is assuranoe the userthatconnectors meeting the to provided requirements this standard performin a satisfactory of will manner, they havebeenproperly selecied the intended for application are installed accordance the manufacturer's in with and recommendations. service The operating conditions the selection the connector and of classis the responsibility the user. of \t Although thereare 12 possible combinations electrical mechanical classes listedin thisstandard, it of and is intended fourto six combinations meetthe usualrequirements a givenrangeof conductor that will for prohibit sizes.Thisdoesnot,however, othercombinations.

{.3

Definitions

bolted-typeconnector:A connector whichthe contactbetween conductor the connector in the and is madeby pressure exertedby one or moreclamping bolts. conductor: Conducting material usedas a carrierof electriccurrent. joining or moreconductors provide continuous path. connector:A device two to a electrical range-taking connector:Connector designed acceptmultiple to conductor sizes. run conductor(main):A continuous conductor fromwhichotherconductors branch.
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joining conductor splice:A connector two ends. tang (pad):The flat portionof a connector usedfor electrical connection. tap conductor: A conduc{or branches fromthe run conductor. that off joining tap conductor a runconductor tap connector:Connector a without to breaking run conductor. the terminal connectors:A connector joins a conductor(s) an electrical that to device.

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@Copyright 2005by the National Electrical Manufacturers Association

ANSfCl19.4-20U

ApplicableStandards
\t

Thisstandard intended be usedin conjunction is to with,butnot limited the following to, standards their in latestedition: ASTM81-01,HardDrawnCopperWre ASTM 82-00, Mediurn-Har&Draw CopperWre n ASTM 88-99, concentric-Lay-stranded copper conductor,Hard, MediurwHad, or soft AsrM 8228-02,c oncentric-Lay-stranded per-cl steelcondu ctors cop ad ASTM 8,22942,Concentic-Lay-Stranded Copperand CoppenCtad SteetComposite Conductors ASTM8230/B230M-99, Aluminum13s0-H19 wre for Electricatpurposes ASTM 8'23118231M-99, Concentric-Lay-Stranded Atuminum1350Conductors (AAC) ASTMB,2321B,232M-01e1, Concentric-Lay-Stranded AluminumConductors, Coated,Steel-Reinforced (ACSR) ASTM8341/8341M-OO, AluminumCoated (Aluminized) Stee/CoreWre for AtuminumConductors, Steel (ACSR/AZ) Reinforced purposes ASTM 8396-00, Aluminum-Alloy 500*H19 Wre for Etectricat ASTM 8397-85(1999),Concentric-Lay-Stranded Aluminur*Attoy500*H19 Conductors purwses ASTM8398/8398M-99, AluminurwAlloy 6201-781 wre for Etectricat ASTM8399/B399M-99, Concentric-Lay-Stranded Atuminum-Atloy 6201-781 Conductors ASTM8400-01 Compact RoundConcentic-Lay-Stranded AluminumConductors , 1350 ASTM 8401-99,CompactRoundConcentric-Lay-Stranded AtuminumConductors, SteelReinforced (ACSR/COMP) ASTM841U98, Har&Dravtn Aluminum-Clad SteetWre ASTM8416-98, concentric-Lay-strandeduminum-ctad steet conductors Al ASTM8498/8498M-98, (Galvanized) Zinc-Coated Steet CoreWre for AtuminumConductors. Sfee/ (ACSR) Reinforced ASTM8500/8500M'98, Metallic coated Stranded Sfee/CoreforAluminumConductors. Steet-Reinforced (ACSR) ASTMB5O2-02, Aluminum-Clad SteelCoreWre for AluminumConductors, AluminumCtad.SteelReinforced ASTM 85241B,524M-99, Concentic-Lay-Stranded Atuminum Conductors, AluminumAttoy Reinforced (ACAR and 1350/6201) ASTM8549-00,Concentric-Lay-stranded AluminumConductors, Aluminurn-Ctad SteetReinforced (ACSR/AW

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ANSfC119.+200/'

V\7

(Galvanized)SteelCorc Wre for Aluminumand AluminurnASTM 8606-98,High-Strength Zinc-Coated AlloyConductors,steelReinforced ASTM8609/8609M-99, Aluminum1350RoundWre,Annealed Tempers, Electical and lntermediate for Purposes ASTM 8701/8701M40,Concentric-Lay-Stranded Self-Damping AluminumConductors, SteelReinforced (ACSR/SD) (AAC/W ASTM 8778-97,Shaped Wre Compact AluminumConductors Concentic-lay-stranded ASTM8779-96,ShapedWre Compact Concentric-lay-stranded AluminumConductors, Steel-reinforced (ACSR/TW) ASTME4-01,Practices Force Veificationof Testing for Machines

3 3.1

Test conditions General

performance accordance Connectors shallbe installed testedfor current-carrying mechanical and and in withthe conditions notedin clauses through 7. 5

3.2
, \z

Gurrentcycle tests

Testsshallbe conducted accordance clause and shallbe of the duration in with 6 listedin Table1, (Current depending the cunentclassof the connector the choice testmethod on and of CycleTesi (CCT) or CunentCycleSubmersion (CCST)). Test Tablel -Testduration ConnectorClass Numberof Test Cyclesfor:
CGT Method CCST Method

ExtraHeavyduty (ClassAA) Heavyduty(Class A) Medium duty(ClassB) Lightduty(Class C)

500 500 250

125

NA 100 75 50

3.3
a

Mechanicaltests

Testsof tensilestrength the connection, of reusability the connector, effecton the strength the of and of iniine conductor shallbe conducted accordance clause for the strength in with 7 classas listedbelow: Class1 - Fulltension Class2 - Partialtension Class3 - Minimum tension

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ANS|C119.+2W

4 4.1

Performance General
\,

performance 4.7, requirements 4.2 through wheninstalled in Connectors shallconform the appropriate to in with specified clauses5 through7. and testedin accordance the methods

4.2

Resistance

is with testedin accordance clause6 shallbe stable. Stability achieved The resistance the connection of for enor,doesnotvaryby morethan if any resistance measurement, induding allowance measurement at intervals duringthe courseof the test. tSolo fromthe average all the measurements specified of 4.2.1 CCTresistance with The resistance the connection testedby the CurrentCycleTest methodin accordance clause6 of of the numberof currentcyclesrequired cycleand the completion shallbe stablebetween twenty-fifih the in 3.2for the connector classtested. 4.2.2 CCSTresistance in Test testedby the CunentCycleSubmersion method accordance The resistance the connection of of with clause6 shallbe stablebetween tenthcycleand the completion the numberof currentcycles the required 3.2for the connector in classbeingtested.

4.3

Temperature

of with The temperature the connector testedin accordance clause6 shallnot exceedthe temperature of shall and between controlconductor the connector the the controlconductor. temperature The difference the conductor the and if difference between control be stable.Stability achieved anytemperature is of for error,is notmorethan 10"Cbelowthe average all connector, including allowance measurement temperature in differences thisinterval. 4.3.1 GCTtemperature the The temperature the connector testedby the CurrentCycleTest methodshallbe stablebetween of in of twenty-fifth cycleand the completion the numberof cunentcyclesrequired 3.2 for the connector classbeingtested. 4.3.2 CCSTtemperature Test methodshallbe stable The temperature the connector testedby the CunentCycleSubmersion of in cyclesrequired 3.2for the of of between tenthcycleandthe completion the number current the conductor classbeingtested.

4.4

Tensilestrength and rated conductor strength

4.4.1 Tensilestrength with shallbe equalto or greater than Thetensile testedin accordance 7.3.4.1 strength the connections of the valueslistedin 4.4.3.

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ANS|C119.+200/.

4.4.2

Ratedconductor strength

Ratedconductor strength, usedin this standard, as shallbe determined accordance the applicable in with ASTMstandard listedin clause2, or as furnished the conductor by manufacturer nonstandard for conductors. 4.4.3 Classesof tensile strength

4.4.3.1Class1, fulltension The tensilestrength shallbe equalto or greaterthan 95%of the ratedconductor strength the weakerof of joined.A conductor the conductors being shallbe considered a failure as whenat leastonestrand breaks. Forconnectors the typethat do not haveseparate of grippingmeansfor the differentmetalsof composite conductors that use nonferrous or meanson fenousconductors cpres,they shallfirst be or testedin accordance 7.3.3.1without with slippage breakage. or 4.4.3.2 Glass2, partialtension Thetensile strength shallbe equalto or greater than40%of the ratedconductor strength the weaker of of joined. the conductors being 4.4.3.3 Glass3, minimumtension The tensilestrength shall be equalto or greaterthan 5% of the ratedconductor strength the weakerof of joinedbut notlessthanthevaluesin Table2. the conductors being Table2-Tensileload \y Wire Size (AWG}
lbr

Pullout
Gopper N*

Aluminum

ACSR

rb
15 25 35 40
45

N*

th

N*

16
14

12 10
I

6 4 3 2
1
* For reference only

30 50 70 80 90 100
140

160
180

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

890*

67* 111* 156* 178* 200*

200

50 70 80 90 100

222*
311* 356* 400* 445*

100 100 150 150 200 200

445'

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

fr' 4.5
\ .l

Reusableconnectors

Uponcompletion all tests,a connector is designated the manufacturer be reusable of that by to shallstill function originally as designed.Reusable means thatthe connector maybe removed fromservice and installed again.Priorto reuse,any reusable connector shallbe reconditioned accordance in with man ufacture/sinstructions.

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ANSfC119.+20U

4.6

Tap connector

test in damage the if, requirement afterperforming conductor the satisfies mechanical A tap connection strength. of its ratedbreaking retainsat least90% 7.5,the run conductor in as requirement stated 4.4.3.3. shall test,tap wireconnection(s) meetthe tensile ln a separate
a

4.7

Torque requirements

of torqueor, in the absence tightening 12Oo/othe manufacture/s of connec{or shallwithstand A bofted part. Damage defined a crack, is as damage anycomponent to thoseshownin Table3 without such, (see7.4). by detected visualmeans Table3 - Tighteningtorquer'2 Galvanized Steel,Stainless Steel or Silicon Bronze Fastener
lb in.

Threaded Fastener Size

In.

Aluminum Fastener

mm* 7.9 9.5 10.3 11.1 12.7 14.3 15.9

lb in.

Nm*

Nm* 20.3 27.1 32.5

40.6

5/16 3/E 13t32 7t16 1t2

9/16

180
168 19.0

240 288 360 480 576 660

2U 240 300
384

23.0 27.1 33.9

43.4

54.2 65.0 74.5

5/8

480

54.2

'For reference only. tForuseonlyin absence the manufac{ure/s recommendation. of 2Connectors be installed supplied the manufacturer. by as to

5 5.1

General Test Procedures, Test connectors

5.1.1 Description in shallbe included compound and conductors, inhibiting of description the testconnectors, A complete the test report(seeclause8). 5.1.2 Familysampleset of a (group connectors design criteria), minimum three usingsimilar of To qualiffa familyof connectors of connector the \Mtenonlyonesmaller-size shall and smallest, intermediate) betested. sizes(largest, is parameter addedto a previously family, additionaltesting notrequired. tested is samedesign
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ANS|Cl19.+20A4

5,2
\/

Test conductors

The conductors usedin thesetestsshallbe unusedbareconductors.Flat barsto whichterminal connectors boltedshallbe considered are conductors. flat-barconductor The shallbe the nearestsize that can be boltedto the terminaland havea cunentcapacity closestto that of the maximum conductor accommodated.

5.3

Test assemblymethods

5.3.1 Installationdetails All installation details, including methods tools,notspecifically and defined required clauses or in 5 through shallbe completely 7, desoibedin thetestreport. 5.3.2 Conductor preparationfor electrical tests The outersurface the conductors the contact of in areashallbe mechanically cleaned usinga wirebrush untilthe entirecontact areaof the conductor clean. is 5.3.3 Conductorpreparation mechanical for tests The portion the conductor is to be inserted the connector of that into shallbe wipedwitha particle-free jelly,unless connector usedwithan inhibiting clothcoated withpetroleum the is compound. 5.3.4 Connectorpreparation Connectors shallbe prepared accordance the manufacturefs in with recommendations.
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5.3.5 Connectorinstallation The methods toolsusedto installthe and connector shallbe in accordance the manufacture/s with recommendations. lnstallation shalltakeplacein an ambient environment between 15"C(59"F)and 35'C (95' F).\Mtenclamping fasteners used,theyshallbe tightened accordance the are in with manufacturefs recommendations. the absence a recommended In of torque, values the specified in Table3 shallbe used.

6 6.1

Current GycleTest Procedures General

Cunentcycletestsshallbe conducted connectors on assembled seriesin a loopin accordance in with cfauses and6.2through 5 6.'12.2. accelerated An current cycletestmethod, referred as the cunent to cyclesubmersion (CCST) is offeredas an altemate test test method usedprimarily quicklyassess to performance. connector The cunentcycletest (CCT)remains preferred methodrecommended the test for the qualification a connec{or. of
NOTE-The CCSTmethod differs ftomthe traditional current cycletest (CCT)in thattestconnectors rapidly are cooledby immersion chilled in urater the beginning the "cunentFF"cycle. Comparative at of testinghasdemonstrated the CCST that methodwill provideessentially sameperformance resultsas the traditional the test currentcycletest (CCT)in fanrier cycles. test

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ANS|C119.+200/.

6.2

Test assembly

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6.2.1 Conductors lf the cunentthrough connector. the to shall combinations be selected maximize 6.2.1.1Conductor conductors, and aluminum-to-aluminum aluminum-to-copper for usebetween is connector recommended it shallbe testedon bothcombinations. the limits cunent, otherconductor the selected wfierethe conductor 6.2.1.2ForClassAA connectors cunentrating. conduc{or shouldbe sizedas closeto butnot lessthanthe limiting
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 as of for of Fourconnectors the samesize andtype are required eachcombination conductors, (pador conductors tang-to-tang to may connectors be connected flat bar in determined 6.2.1.Terminal to'pad).

6.3

Equalizers

of the and planes resistance measurements to prevent influence one for To provide equipotential on eachsideof eachconnector conductor in shallbe installed stranded equalizers on connec{or another, (pad-to-pad). tang-to-tang are connectors tested wheretwoterminal in the cunentcycleloop,'except permanent contact that Anyformof equalizer ensures on are Equalizers not required solidconductors. maybe used. for strands the testduration amongall the conductor 6.3.{ Weldedequalizerc

are equalizers madeftom Welded conductors. for is equalizer recommended aluminum A welded aluminum 6.3.2 Compressionsleeveequalizerc may be usedbetween pieceof conductor a to \Mrenthe connectors be testedare identical, continuous with as is sleeve employed an equalizer in withan equalizer the center.lf a compression the connec{ors, as be should prepared in 5'3.1 areaof the equalizer in the conduc{ors, conductor the contact aluminum and5.3.2.

6.4

Gonductorlengths

the or and the between connector the equalizer, between conductor lengthof stranded The exposed with in of connectors solidconduc{ors the cunentcycleloop,shallbe in accordance Table4. lf a flat bus its terminalconnectors, lengthshallbe twicethat shownin table4 for the stranded bar is usedbetween beingusedin the of or size conductor beingusedin theterminal, the samelength the solidconductor or withinthe connector equalizer. the include length in length Table4 doesnot terminal.Theconductor end permits, conductor shallprojectll2inch (12'7 mm)beyond the whereconnec{oidesign ln addition, at contactgroove.Thl equalizers eachend of the currentcycleloopshallbe joinedto the the connector in to lengthsof the test conductor be not lessthanthe lengthsspecified powersouroe with additional 4. Table

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ANS|C119.+20U

Table 4 - Gonductorlengths for current cycle tests

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ExposedLength Aluminumor AluminumComposite Gopperor CoooerComoosite

Stranded tn. Solid tn.

mm* 305 610

914

mm*
610 1219

Up through4/0 AWG Over4/0 A\A/G through 795 kcmil Over795 kcmil

Up through A\ re 2/0 Over 2/0 AWG through 500 kcmil Over500 kcmil

12 24 36

24
48

72

1829

6.5

Gontrol conductor

two in A controlconduc{or, determining current,shallbe installed the cunentcycleloop (between for test equalizers stranded for conduc{ors). control The conductor shallbe the sametypeand sizeas the lts shallbe twicethat in temperature. length conductor the cunentcycleloopthatwouldbe at the highest givenin Table4. ForClassAA,whenthe control see is conductor copper, 6.5.2.

6.5.1 Equivalentaluminum/copperconductors fromTable maybe determined selecting by At the manufac{ure/s option, sizeof the control the conductor aluminum/copper in 5 the conductor the cunentcycleloopthathasthe leastcunentfor equivalent conductors. 6.5.2 Multiplecontrol conductors causes arises to whichconductor as 6.5.2.1 lf the testloopincludes different conductors, a question and Thetestcunentshallcause rise, the highest temperature a control conductor eachtypeis required. of of the higher temperature in oneof the control rise conductors meetthe requirements 6.8. to control thena second 6.5.2.2ForClass AA, if the conductor determining cunentis copper, for test control cable for stabili$.The second conductor aluminum of shallbe included the purpose evaluating of the shallbe of the closest ampacity chosen and based the valuesshownin Table5. However, copper on control conductor shallbe usedfor establishing current the withinthefirst25 cycles.

6.6

Loop configurationand location

6.6.1 CCTmethod are The cunentcycleloop may be of any shapeprovided connectors the controlconductor and the plane, between and installed the samehorizontal in withat leastan 8 in. (203mm)separation conductors located least1 ft (305mm)fromanywallandat least2 ft (610mm)ftomthefloorandthe ceiling. at
NOTE-This assu.esthat the contsol conductor the @nnec{ors beginthe nextcunent-ONperiodat the sametemperature. and

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ANS|C119.+2004

6.6.2

CCSTmethod

the planeas the testconnectors. During on shallbe installed the samehorizontal conduc{or The control of period, partof the circuit shallbe lessthan8 in. (200mm)abovethe surface the chilled no cunent-ON shallbe period,the connectors the controlconductor and of water. At the beginning the cunent-OFF watersurface. of to submerged a minimum 4 in. (100mm)belowthe
periodat the sametemperature. beginthe nex cunent-ON and conductor the @nnectors that NOTE-This assures the control

100"C Table5 - Suggestedinitialtest currentto raise control conductortemperature Aluminumor AluminumComposite Conductor (AwG)
6
4

Copper or CopperComposite Conductor (AwG)

8 6 4

Current (Amperes)
90 125
170

Current (Amperes)
95 130 180 245 340 400
470

2
1

200 230 270 320 380

1n

1to

2n
3 )

ao
3/0 4to
(kcmil)

4n
(kcmil) 266.8

550

450 525
590 670 7fi

2n
300 350 400 500 750

615 700 780 850 990 1300 1565

336.4 397.5 477 a56.5 636 795

954

820 955 1085 1150 1220 1275 't350 1390 1450 1560

1mo

1033.5 1113 1192 1272 1351.5 1431 1590

10

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ANSIC119.+2004

6.7
\'

Ambientconditions

Cunentcycletestsshallbe conducted a spacefree fromforcedair cunentsor radiated in heatstriking (directly indirectly) portion the testloopduring current-ON period.Theambient or any of the temperature shallbe held between15"Cand 35'C.
I

6.8

Test current

Thecunentvaluesin Table5 arethe suggested initial amperes thisstandard Class B, and test for for A, C and havebeenselected simplify to currentselection orderto achievethe required in temperature in rise the control largerthanthoseshownin Table5, the current determined conductor. conductors For is by reaching stabletemperature. a Thesecunentsare not intended suggestcurrentvaluesfor use in to actualservice.ClassAA test currents established obtaining propertemperature are by the rise. 6.8.1 CCT temperature conditions The cunentcycletest currentshallbe adjusted duringthe cunent-ONperiodof the first twen$-fivecycles to resultin a steady-state rise temperature on thecontrol conductor 100"Cto 105"Coverambient of temperature ClassA, B, andC. The ClassAA risewill be 175"C 180'Coverambient for to temperature. periods, Thiscunentshallthenbe usedduring remainder the testcunent-ON the of regardless the of temperature the controlconductor. of 6.8.2 CCSTtemperature conditions The cunentcyclesubmersion current period the first five test shallbe adjusted the during current-ON of cydes to resultin a steady-state temperature on the controlconductor 100'C to 105'C over rise of ambient temperature. Thiscunentshallthenbe usedduring remainder thetestcurrent-ON the of periods, regardless the temperature the controlconductor. of of 6.8.3 CGTmethodelevated temperature currentstabillzation The cunentcycletest currentshallbe increased fromthat shownin Table5 to achieve appropriate the elevated temperature withinthe firsttwenty-five cycles. 6.8.4 CCSTmethod elevatedtemperaturecurrent stabilization The cunentcyclesubmersion cunentshallbe increased fromthat shownin Table5 to achieve test the appropriate elevated temperature withinthe firstfive cydes.

^ \,

6.9

Current cycle period

period.Thetimerequired make Eachtestcycleshallconsist a cunent-ON a current-OFF of and to resistance temperature measurements not considered partof the cunent-ON cunent-OFF and is a or time periods.
?

'

6.9.1 Gurrentcycle0N period period The length the current-ON of shallbe as listedin Table6, depending the sizeof the control on conductor. conductors For larger thanthoseshownin Table6, the current-ON is determined time by reaching maintaining and thermal stability the connector. in Thermal stability defined not morethan is as a variation 2C between two of threereadings of any takenat notlessthan 10 minintervals.

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11

ANS|C119.+200/

Table 6 - Current cycle periods for control conductorc AluminumorAluminum Composite(kcmil) 336.4 Up through 795 Over336.4through 1590 Over795through Copper or Copper Gomposite #4/0 A\ rG Up through AWGthrough500 Over#4/O kcmil 1000 through Over500 kcmil kcmil Current0N Period (Hour) 1.0 1.5 2.O

6.9.2 CCTcurrentcycleOFF period air. temperature The shallcoolin ambient CycleTest(CCT)method testedby the Current Connectors periodfor connectors testedby the CCT methodshallinitiallybe the same time lengthof the cunent-OFF period. The time lengthmay be reducedby forcedair coolingafterthe firsttwenty-five as the cunent-ON duringthe current-OFF forcedair coolingmay be initiated concunence, cycles. \Afith manufacture/s the periodshallbe established by cunent-OFF periodafierthe first cycle. The time lengthfor the reduced temperature. to for 5 adding minto thetimerequired thefourconnectors reachambient 6.9.3 CCSTcurrentcycleFF period in shallbe immersed still, method Test testedby the CunentCycleSubmersion (CCST) Connectors period.Theconnectors shall + 4"C)within30 seconds the startof the cunent-OFF of water(5.C chilled is of for a minimum 15 minafterthe temperature the connector of water in immersed the chilled remain fromthe waterbeforethey shallbe removed of the water. The connectors to reduced the temperature cycle. of at are energized the beginning the nextcurrent-ON

6.10 Measurements
on to measurements be madeaccording Table7, depending the choice shall Resistance temperature and in thosespecified Table7, the datumsexceeds test method.\Mrenthe numberof measurement of performance ClassA, B, and C for cycleshallbe usedto evaluate nearesteachspecified measurements shallbe takena measurements resistance temperature and connectors.For ClassAA connectors, minimum onceeverytwentycycles. of

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Association Manufadurers Electrical 2005by the National @Copyright

ANSfCl19.+2004

Table 7 - Resistanceand temperaturemeasurementinteryals*

\/

Current Cycle Test Method(CCT) (Cycles)

25-30 45-55 70-80 95 - 105 120 130 160 170 2@-2'tO 245-255 320 - 330 400- 410 495 - 505 ' Doesnot applyto ClassAA Connec{ors.

CurrentCycleSubmersion Test Method(CCST) (Gycles)

5-7 8- 12 1 8- 2 2 28-32 38- 42 4a-52 58-62 68-72 78-82
88-92

98 - 102

6.10.1 Resistance measurements

\,

period Resistance measurements be madeat the end of a current-OFF shall withall connectors thermally stabilized the roomambient at temperature. Thermal is stability defined not morethana variation as of 2"C between two of threereadings any takenat not lessthan 10 min intervals.Resistance potential pointslocatedeitheron the mea$Irements shallbe madeacrosseachconnector, between equalizers maximum one conductor a of diameter fromthe edgeadjacent the conductor at the to or midpoint a solidconductor. lowmagnitude of A directcunentnotto exceed12Ashallbe usedfor these measurements. Ambient temperature shallbe measured within2 ft (610mm)of thetestloopat a location that minimizes effectof thermalconvection.The ambient the temperature shallbe recorded at the time of eachset of resistance measurements. resistance eachconnector The of assembly shallbe conectedfromthe measured temperature 20'C. The conec{ed to resistance valuesshall be usedto evaluate performance the connectors. the of
NOTE-The resistance valuesobtained shallbe conected 20'C withthefolloadng to formula:

R z o = R ,l 1 1+ s ( T m - 2 0 ) l ('C) \Mtere R. is the measured resistance, is the temperature of the connector cris the resistance T, and variation coefficient the temperature. with This coefficient be takenequalto: can
{

I
I
I

cr= 4 X 1O{/"C copper ACSR for and cr= 3.6X 1O/'C aluminum for 6.10.2 Temperature measurements

Temperature measurements the connec{ors, of controlconductors, ambientair shallbe madeat the and end of the specified cunent-ON cycle,immediately beforethe currentis tumedoff. The temperatures

@Copyright 2005 by the National Electrical Manufacturers Association

13

ANSfC119.+200/for installed the cunentcycle that shallbe measured meansof thermocouples havebeenpermanently by at in shallbe installed the cunentpathof eachconnector a pointwhere tests. At leastonethermocouple of at shall is Onethermocouple be installed the midpoint the control the highest temperature anticipated. conductor.

6.11 Maximumnumber of current cycles

the to taking in the specified 3.2,Table1, to complete testmaybe extended permit The number cycles of hours. duringnormal working finalmeasurements

6.12 Evaluationinterval
performance, specified 4.2 and4.3,shallbe madeon the basisof in as The evaluation the connector of measurements. resistance temperature and 6.12.1 Evaluation the GGTmethod by with measurements takenin accordance 6.10shallbe usedto evaluate The resistance temperature and testedby the CurrentCycleTest (CCT)method. connectors by 6.12.2 Evaluation the CCSTmethod 6.10shallbe usedto with measurements taken in accordance section The resistance temperature and Test (CCST)method. evaluate connectors testedby the CunentCycleSubmersion

7 7.1

procedures Mechanicaltest General

7.5. with 5 in Mechanicaltests be conducted accordance clause and7.2through shall

7.2

Test connectors

to shall combination be subjected eachmechanical 7.2.1 Threesamples eachconnector-conductor of in testdescribed 7.3.7.4. and7.5. thatthe samedesign it shallbe testedunless can be shown 7.2.2 Bothdeadends splices and pararneters materials usedfor bothdevices. lf onlyone deviceis tested,it shallbe the deadend. are and

7.3

Pullouttest

for combinations whichthe two on 7.3.1 Pullout strength testsshallbe performed thefollowing conductor connector designed: is (1) (2) conductor and The highest ratedtensile strength strength. ratedtensile of The smallest diameter conductor the highest

joiningtechniques be required the connector manufacturer and may special NOTE-lf the conduc{or has beengrease-filled, core shouldbe consulted.

the and/ormaterials, test shallbe run on 7.3.2 lt the connectors be usedon different can construction ACSR,AAC,AAC/TW, etc. category suchas eachconductor

\t
14 Association Manufacturers 2005by the National Electrical @Copyright

ANS|C119.+2004. 7.3.3 Tensilestrength \, loadtesting. loadtestingand maximum shallbe usedfor boththe sustained The samesamples testsis permissible. Relaxation tensionbetween of 7.3.3.1Sustainedload gripping means installed of connectors the typethatdo not haveseparately 7.3.3.1.1Class1, full-tension or meanson ferrousconductors or metalsof composite conductors, whichuse nonferrous for the different in A in as the cores,shallfirstbe testedby installing connectors assemblies described 7.3.3.1.2. constant shall as t of of loadequalto77o/o 5olo the ratedstrength the conductor, determinedin4.4.2, be tensile for of on applied and maintained the assemblies a minimum 168hours. and means eachgripping in between of conductor the testassembly 7.3.3.1.2The length the exposed of capable meansmaybe any device shallbe at least12ft (3.66meters).The gripping eachconneclor connector the same of gripping strands without slippage the duration the test. lf another for of all securely as beingtestedis used,it mayalso be considered a test connector. type as the connector 7.3.1 Maximumload of thatall strands the strength test,careshallbe takento ensure 7.3.4.1\Mrenconducting tensile the are simultaneously. conductor loaded 114 at speednotexceeding in. per minperft (20.8mm per 7.3.4.2The loadshallbe applied a cross-head jaws. conductor between min per m) of the total lengthof the exposed shallnot means andeachconnector conductor between eachgripping 7.3.4.3The length the exposed of be lessthanthatgivenin Table8. \loadthatcan be applied.Thisload shallbe determined the maximum as 7.g.4.4Thetensile strength with for for and to ol shallbe measured an accuracy 1o/o Class1 connectors 5olo Class2 and3 connectors shallbe recorded. according ASTME4. The modeof failure to instruments calibrated in valuesindicated 4.4.3are required. 7.3.4.5Minimum

7.4

Torque strength test

of usingconductors the largest shallbe measured of 7.4.1 The torquestrength the boltedconnector (see4.7). for is diameters whichthe connector designed and smallest within2%. device thatis accurate values usinga measuring torque shallbe measured 7.1.2 Tightening torqueat is valueof the bolttightening of connector the threshold 7.4.3 Thetorquestrength a bolted its occurs thatimpairs proper of component whichrupture permanent or distortion anyconnector was for functioning anyof the conductor on combinations whichthe connector designed.

7.5

Conductordamagetest

and on shallbe performed maximurn-run 7.5,1 The conductor damage for the tap connector test In is of minimunrrun conductors eachtypefor whichthe connector designed. all tests,the maximumshallbe used. is temperfor whichthe connector designed tap of diameter conductor the hardest gripping meansis as whoselength between shallbe installed a runconductor on 7.5.2 A tap connector in as 20o/o its ratedstrength determined of as specified Class1 in Table8, and is undera tensileloadof
\-.

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15

ANS|C119.+2W The shallthenbe installation. conductor connector of 4.4.2. Relaxation the loadshallnotoccurduring point. breaking to stressed the Table 8 - Length of exposedconductor Connector Class Description Length lnches Class1 (a)
(b)

Meters
0.61

alloy for Intended singlemetalorsingle or with conductors 19 strands less. alloy for Intended singlemetalor single with conductors morethan 19 strands alloy metalormultiple for Intended multiple conductors

24 1M*
144'

3,66* 3.66*
0.61

(c) Class2 Class3

24 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 loading of all strands. 24 in. (0.61 m), if proceduresensure simultianeous

Test report

to or conformance nonconformancethe data the shallinclude necessary to support Thetestreport and of requirements thisstandard, alsothe following: Dateof test of Description test assemblies beforetestingto ensuretraceability compound and Description connectors inhibiting of strengths ratedconductor including of Description conduc{ors, procedure of Description connectorinstallation Cunentcycleamperage afiertesting of Description the condition connectors of Electrical: ClassAA,A, B, C Class1,2, 3 Mechanical: Method: CCT,CCST performing test the Narneand addressof the test facilityand the namesof the technicians of (drilled surface mounted) or method the of All options usedin performance the testincluding mounting (diagrams photographs the testsetupare desirable) of or the thermocouples in definedor required this standard detailsnot specifically information, suchas installation Otherpertinent Certifi cation(if required)

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