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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 \,

ffi
ANS! C119.4-2004

American
NationalStandard
V ForElectricConnectors-

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

Secretariat:

NationalElectricalManufacturersAssociation
ApprovedDecember30, 2004

American NationalStandardsInstitute,Inc.

\,
 ANSfC119.+2004

Contents

Page

Foreword

@Copyright2005by the NationalElectricalManuf;acturers

Association ill
ANS|C119.+2M

preparation.............
5.3.4 Connector .................7
5.3.5 Conneclor
installation ............7
Cunentcycfetestprocedures ....................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 ....................9
6.5.2 Multiple
control
conductors. ......................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 ......11
6.8 Testcunent ..................
11
6.8.1 CCTtemperature
conditions ..................
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.............. .....13
6.10.2 Temperature
measurements.............. .....................
13
6.1{ Maximum
number
of cunentcycles ..................14
6.12 Evaluatio
i nnt e r v a | . . . . . . . . . . . . . . . . . . ........14
6.12.1 Evaluation
by theCCTmethod................ ...............14
6.12.2 Evaluation
by theCCSTmethod ..........14
procedures.............
Mechanicaltest ........14
7.1 General .....14
7 , 2 T e s tc o n n e c t o r s . . . . . . . . . . . . . .................14

iv @Copyright2005by the NationalElectricalManufac{urers

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 ANS|C119.+2004

7 . 3 P u l l o ut et s t . . . . . . . . . . . . . ......14
7.4 Torquestrength
test............ ...........15
7.5 Conductordamagetest............. ..... 15
Testreport ..........16

Tables
1 Testduration ........3
2 Tensile
load ..........5
3 Tightening
torque .....................6
4 Conductor
lengthsfor cunentcycletests.. g
.....................
5 Suggested
initialtestcunentto raisecontrolconductor
temperature
100.C.......................
1o
6 Cunentcycleperiodsfor controlconductors. ..............12
7 Resistance
andtemperature
measurement
intervals ....................
13
8 Length
of exposed
conductor ...................
16

@copyright2005by the NationatElectricalManufacturers

Association
ANS|C119.+2004

is notpartofAmerican
FOfewOfd fihis Foraaord National
Standard
C11g.4-2OO4.l

This standarddescribescunentcycleand mechanicaltests usedto establishperformance

characteristics
of connectorsusedto 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)utilizingelevatedtemperaturetesting

for an extraheavyduty connectorcategory,ClassAA. The intentof elevatedtesttemperaturein Class
AA testingis to providea betterperformingconnector.

Thisstandardwas initiallydevelopedunderthe directionof the Transmissionand Distribution

Committee
of the EdisonElectricInstitute(EEl). Tentativeperformance-type
specifications
for electrical
characteristicswereissuedin jointreportformin 1958by a steeringcommittee of EEIand an advisory
committee of manufac{urers on the aluminumconductorresearchproject(EEl Pub.No.59-70,Tentative
Specificationsfor 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.

Suggestionsfor 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 Connectorsfor Electrical
UtilityApplications,
C119. Committeeapprovalof thisstandard
doesnotnecessarily implythatall committeemembersvotedfor its approval.At the timeit approvedthis
standard,the C119Committeehadthefollowingmembers:

DouglasHarms,Chairpetson
RonaldLai,Vice Ghairperson
VinceBaclawski,Secretary

Organizations Represenfed; Nameof Representative:

t
AluminumAssociation Jean-Marie
Asselin
EdisonElectricInstitute WanenHadley
DouglasHarms
JamesHanis
HarryHayes
CurtSchultz
GeraldWasielewski

VI @Copyright2005by the NationalElectricalManufac{urers

Association
 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 C119.4Subcommitteeon Connectorsfor UseBetweenAluminum-to-Aluminum or Aluminum-to-

CopperConductors, the revisionsof thisstandard,hadthefollowingmembersat the
whichdeveloped
timeof approval:

DouglasHarms,Chairperson
v 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
N
Gerald\Albsielewski
DavidWest
AllenWlcox
JamesZahnen

@Copyright2005by the NationalElectricalManuf;acturers

Association vtl
 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{orsusedon distribution
andtransmissionlinesfor electricutility.

Thisstandardestablishes the electricaland mechanical

test requirementsfor electricalconnectors.This
standardis not intendedto recommend operatingconditions
or temperatures.

1.2 Purpose
The purposeof thisstandardis to givereasonable assuranoe to the userthatconnectors meetingthe
requirements of this standardwill performin a satisfactorymanner,providedthey havebeenproperly
seleciedfor the intendedapplication andare installedin accordance withthe manufacturer's
recommendations. Theserviceoperatingconditions andthe selectionof the connectorclassis the
responsibility
of the user.

\t Althoughthereare 12 possiblecombinations of electricaland mechanical

classeslistedin thisstandard,it
is intendedthatfourto six combinations
will meetthe usualrequirementsfor 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 to a runconductor
withoutbreakingthe run conductor.

terminal connectors:A connectorthatjoins a conductor(s)

to an electricaldevice.

v
@Copyright2005by the NationalElectricalManufacturers
Association
ANSfCl19.4-20U

2 ApplicableStandards
Thisstandardis intendedto be usedin conjunction
with,butnot limitedto, the followingstandardsin their \t
latestedition:

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

AluminurwAlloy6201-781wre for Etectricatpurwses

ASTM8398/8398M-99,

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)
t
ASTMB5O2-02,
Aluminum-CladSteelCoreWre for AluminumConductors,
AluminumCtad.Steel-
Reinforced

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 @Copyright2005by the NationalElectricalManufacturers

Association
 ANSfC119.+200/'

ASTM 8606-98,High-StrengthZinc-Coated(Galvanized)SteelCorc Wre for Aluminumand Aluminurn-

V\7 AlloyConductors,steelReinforced

ASTM8609/8609M-99,
Aluminum1350RoundWre,Annealedand lntermediateTempers,for Electical
Purposes

ASTM 8701/8701M40,Concentric-Lay-Stranded
Self-Damping
AluminumConductors,SteelReinforced
(ACSR/SD)

AluminumConductors(AAC/W
ASTM 8778-97,ShapedWre CompactConcentic-lay-stranded

ASTM8779-96,ShapedWre CompactConcentric-lay-stranded
AluminumConductors,Steel-reinforced
(ACSR/TW)

ASTME4-01,Practicesfor Force Veificationof TestingMachines

3 Test conditions
3.1 General
and mechanicalperformancein accordance
Connectorsshallbe installedand testedfor current-carrying
withthe conditions
notedin clauses5 through7.

3.2 Gurrentcycle tests

, Testsshallbe conductedin accordance withclause6 and shallbe of the durationlistedin Table1,
\z dependingon the cunentclassof the connectorandthe 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

v
@Copyright2005by the NationalElectricalManufacturers
Association
ANS|C119.+2W

4 Performance
4.1 General \,

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

4.2 Resistance
The resistanceof the connectiontestedin accordancewith clause6 shallbe stable. Stabilityis achieved
if any resistance
measurement, indudingallowance for measurement enor,doesnotvaryby morethan
tSolofromthe averageof all the measurements at specifiedintervalsduringthe courseof the test.

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 connectorclasstested.

4.2.2 CCSTresistance

The resistance testedby the CunentCycleSubmersion

of the connection Testmethodin accordance
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
be stable.Stabilityis achievedif anytemperature
difference betweenthe controlconductorandthe
connector, includingallowance error,is notmorethan 10"Cbelowthe averageof all
for measurement
temperature differencesin thisinterval.

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

betweenthetenthcycleandthe completion of the numberof currentcyclesrequiredin 3.2for the
conductorclassbeingtested.

4.4 Tensilestrength and rated conductor strength

4.4.1 Tensilestrength

Thetensilestrengthof the connections with7.3.4.1shallbe equalto or greaterthan

testedin accordance
the valueslistedin 4.4.3.

4 @Copyright2005by the NationalElectricalManufac{urers

Association
 ANS|C119.+200/.

4.4.2 Ratedconductor strength

v Ratedconductorstrength,as usedin this standard,shallbe determinedin accordancewith the applicable
ASTMstandardlistedin clause2, or as furnishedby the conductormanufacturerfor nonstandard
conductors.

I 4.4.3 Classesof tensile strength

t 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 conductorsbeingjoined.

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 Pullout
Size
(AWG} Gopper Aluminum ACSR
lbr N* rb N* th N*
16 30 133* 15 67*
14 50 222" 25 111*
12 70 311* 35 156*
10 80 356* 40 178*
I 90 400* 45 200* 100 445'
6 100 445* 50 222* 100 4/.5*
4 140 623* 70 311* 150 667*
3 160 712* 80 356* 150 667*
2 180 801* 90 400* 200 890*
1 200 890* 100 445* 200 890'
* For referenceonly
fr'
4.5 Reusableconnectors
\
.l
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.

v
@Copyright2005by the NationalElectricalManufacturers
Association
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

A boftedconnec{or of the manufacture/s
shallwithstand12Oo/o torqueor, in the absenceof
tightening
such,thoseshown in Table3 damage
without to any componentpart. Damageis definedas a crack,
detectedby visualmeans(see7.4).

Table3 - Tighteningtorquer'2

Galvanized
Threaded Aluminum Steel,Stainless
Fastener Fastener Steel
Size or Silicon
Bronze Fastener
In. mm* lb in. Nm* lb in. Nm*

5/16 7.9 180 20.3

3/E 9.5 168 19.0 240 27.1

13t32 10.3 2U 23.0 288 32.5

7t16 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

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

5 Test Procedures,General
5.1 Test connectors
5.1.1 Description i
A completedescription conductors,
of the testconnectors, compoundshallbe includedin
andinhibiting {
the test report(seeclause8). I

5.1.2 Familysampleset 1
To qualiffa familyof connectors(groupof connectors usingsimilardesigncriteria),a minimumof three
sizes(largest,smallest,and intermediate)shallbetested.\Mtenonlyonesmaller-size connectorof the
samedesign parameter is added to a previously
testedfamily, is
additionaltesting not required.

6 Association
@Copyright2005by the NationalElectricalManufacturers
 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
clothcoatedwithpetroleum jelly,unlessthe connectoris usedwithan inhibitingcompound.

5.3.4 Connectorpreparation

Connectorsshallbe preparedin accordancewiththe manufacturefsrecommendations.

\- 5.3.5 Connectorinstallation

The methodsandtoolsusedto installtheconnectorshallbe in accordance withthe manufacture/s

recommendations. lnstallation
shalltakeplacein an ambientenvironmentbetween15"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.

@Copyright2005by the NationalElectricalManufac{urers

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ANS|C119.+200/.

6.2 Test assembly \,

6.2.1 Conductors

6.2.1.1Conductor combinationsshallbe selectedto maximizecunentthroughthe connector.lf the

connectoris recommended for use betweenaluminum-to-aluminumandaluminum-to-copper conductors,
it shallbe testedon bothcombinations.

6.2.1.2ForClassAA connectors wfierethe conductorselectedlimitsthe cunent,the otherconductor

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

in 6.2.1.Terminalconnectors
determined maybe connected (pad-
or tang-to-tang
to flat barconductors
to'pad).

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

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

withan equalizerin the center.lf a compression
the connec{ors, sleeveis employedas an equalizerwith
aluminumconduc{ors, the conductorin the contactareaof the equalizershouldbe preparedas in 5'3.1
and5.3.2.

6.4 Gonductorlengths
The exposedlengthof strandedconductorbetweenthe connectorand the equalizer,or betweenthe
connectors of solidconduc{orsin the cunentcycleloop,shallbe in accordance withTable4. lf a flat bus
bar is usedbetweenterminalconnectors,its lengthshallbe twicethat shown table4 for the stranded
in
conductorsizebeingusedin theterminal,or the samelengthof the solidconductorbeingusedin the sI
terminal.Theconductorlengthin Table4 doesnotincludethe lengthwithinthe connectoror equalizer.
ln addition,whereconnec{oidesign permits,the conductorendshallprojectll2inch (12'7 mm)beyond
the currentcycleloopshallbe joinedto the
I

the connectorcontact groove. Thl equalizers at eachend of

i
powersouroewith additionallengthsof the test conductorto be not lessthanthe lengthsspecifiedin
Table4. i
'

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@copyright2005by the NationalElectricalManufacturers
 ANS|C119.+20U

Table 4 - Gonductorlengths for current cycle tests

\-'
ExposedLength
Aluminumor Gopperor
AluminumComposite CoooerComoosite
Stranded Solid

tn. mm* tn. mm*

Up through4/0 AWG Up through2/0A\ re 12 305 24 610

Over4/0 A\A/G Over 2/0 AWG 24 610 48 1219

through795 kcmil through500 kcmil
Over795 kcmil Over500 kcmil 36 914 72 1829

6.5 Gontrol conductor

A controlconduc{or,for determiningtest current,shallbe installedin the cunentcycleloop (betweentwo
equalizersfor 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.

6.5.1 Equivalentaluminum/copperconductors
v At the manufac{ure/s by selectingfromTable
option,the sizeof the controlconductormaybe determined
5 the conductorin the cunentcycleloopthathasthe leastcunentfor equivalentaluminum/copper
conductors.

6.5.2 Multiplecontrol conductors

6.5.2.1 lf the testloopincludesdifferentconductors,and a questionarisesas to whichconductorcauses

the highesttemperature rise,a controlconductorof eachtypeis required.Thetestcunentshallcause
the highertemperature risein oneof the controlconductorsto meetthe requirementsof 6.8.

6.5.2.2ForClassAA, if the conductor testcunentis copper,thena secondcontrol

for determining
conductorof aluminumshallbe includedfor the purposeof evaluatingstabili$.The secondcontrolcable
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
installedin the samehorizontal betweenconductorsand
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

The controlconduc{or shallbe installedon the samehorizontal planeas the testconnectors.Duringthe

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

Table5 - Suggestedinitialtest currentto raise control conductortemperature100"C

Aluminumor Copper or
AluminumComposite CopperComposite
Conductor Current Conductor Current
(AwG) (Amperes) (AwG) (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
3/0 470
3 ) 320

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

a56.5 7fi 500 990

636 820 750 1300

795 955 1mo 1565

954 1085

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)
any portionof the testloopduringthe current-ON
period.Theambienttemperature
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-statetemperatureriseon thecontrolconductorof 100"Cto 105"Coverambient
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 testcurrentshallbe adjustedduringthe current-ON periodof the first five

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

Eachtestcycleshallconsistof a cunent-ONanda current-OFF period.Thetimerequiredto make
resistanceand temperaturemeasurements is not considereda partof the cunent-ONor cunent-OFFtime
periods.
?
'
6.9.1 Gurrentcycle0N period

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

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Association 11
ANS|C119.+200/

Table 6 - Current cycle periods for control conductorc

v
AluminumorAluminum Copper or Copper Gomposite Current0N Period
Composite(kcmil) (Hour)

Up through336.4 Up through#4/0 A\ rG 1.0

Over336.4through795 Over#4/OAWGthrough500 1.5

kcmil
Over795through1590 Over500 kcmilthrough1000 2.O
kcmil

6.9.2 CCTcurrentcycleOFF period

Connectors testedby the CurrentCycleTest(CCT)methodshallcoolin ambienttemperature air. The

time lengthof the cunent-OFF period for connectors tested by the CCT method shallinitiallybe the same
as the cunent-ON period. The time length may be reduced by forcedair coolingafterthe first twenty-five
cycles. \Afiththe manufacture/sconcunence,forcedair coolingmay be initiatedduringthe current-OFF
periodafierthe first cycle. The time lengthfor the reducedcunent-OFFperiodshallbe establishedby
adding5 minto thetimerequiredfor thefourconnectors to reachambienttemperature.

6.9.3 CCSTcurrentcycle€FF period

Connectors testedby the CunentCycleSubmersion Test(CCST)methodshallbe immersedin still,

chilledwater(5.C 4"C)within30 secondsof the startof the cunent-OFFperiod.Theconnectors
+ shall
remainimmersedin the chilledwater a for minimumof 15 minafterthe temperatureof the connectoris
reducedto the temperature of the water. The shall
connectors be removed from the water beforethey
are energizedat the beginningof the nextcurrent-ONcycle.

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

i
1

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 ANSfCl19.+2004

Table 7 - Resistanceand temperaturemeasurementinteryals*

\/
Current Cycle Test Method(CCT) CurrentCycleSubmersion
(Cycles) 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 98 - 102

' Doesnot applyto ClassAA Connec{ors.

6.10.1 Resistancemeasurements

Resistance measurements shallbe madeat the end of a current-OFFperiodwithall connectors

thermally
\, stabilizedat 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

Temperaturemeasurements of the connec{ors,controlconductors,and ambientair shallbe madeat the

v end of the specifiedcunent-ONcycle,immediatelybeforethe currentis tumedoff. The temperatures

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Association 13
ANSfC119.+200/-

shallbe measuredby meansof thermocouples that havebeenpermanentlyinstalledfor the cunentcycle

tests. At leastonethermocouple shallbe installedin the cunentpathof eachconnectorat a pointwhere
the highesttemperatureis anticipated.Onethermocouple shallbe installedat the midpointof the control V
conductor.

6.11 Maximumnumber of current cycles

The numberof cyclesspecifiedin 3.2,Table1, to completethe testmaybe extendedto permittakingthe
finalmeasurementsduringnormalworkinghours.

6.12 Evaluationinterval
The evaluation as specifiedin 4.2 and4.3,shallbe madeon the basisof
of the connectorperformance,
resistanceand temperaturemeasurements.

6.12.1 Evaluationby the GGTmethod

The resistance
andtemperature measurements with6.10shallbe usedto evaluate
takenin accordance
connectorstestedby the CurrentCycleTest (CCT)method.

6.12.2 Evaluationby the CCSTmethod

The resistance
andtemperature measurements withsection6.10shallbe usedto
taken in accordance
evaluateconnectorstestedby the CunentCycleSubmersionTest (CCST)method.

7 Mechanicaltestprocedures
7.1 General
withclause5 and7.2through7.5.
shallbe conductedin accordance
Mechanicaltests

7.2 Test connectors

combination
7.2.1 Threesamplesof eachconnector-conductor to eachmechanical
shallbe subjected
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
7.3.1 Pulloutstrengthtestsshallbe performed for whichthe
combinations
on thefollowingtwo conductor
connectoris designed:

(1) The highestratedtensilestrengthconductorand

(2) The smallestdiameterconductorof the highestratedtensilestrength.
specialjoiningtechniques
corehas beengrease-filled,
NOTE-lf the conduc{or maybe requiredandthe connectormanufacturer
shouldbe consulted.

7.3.2 lt the connectorscan be usedon differentconstructionand/ormaterials,the test shallbe run on

eachconductorcategorysuchas ACSR,AAC,AAC/TW,etc.

\t

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7.3.3 Tensilestrength

\, The samesamplesshallbe usedfor boththe sustainedloadtestingand maximumloadtesting.

Relaxationof tensionbetweentestsis permissible.

7.3.3.1Sustainedload

7.3.3.1.1Class1, full-tension connectorsof the typethatdo not haveseparatelyinstalledgrippingmeans

for the differentmetalsof compositeconductors,or whichuse nonferrousmeanson ferrousconductorsor
cores,shallfirstbe testedby installing
the connectors in assembliesas describedin 7.3.3.1.2.A constant
tensileloadequalto77o/ot 5oloof the ratedstrengthof the conductor,as determinedin4.4.2, shallbe
appliedand maintained on the assembliesfor a minimumof 168hours.

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\Mrenconductingthetensilestrengthtest,careshallbe takento ensurethatall strandsof the

conductorare loadedsimultaneously.

7.3.4.2The loadshallbe appliedat a cross-head speednotexceeding114in. per minperft (20.8mm per

min per m) of the total lengthof the exposedconductorbetweenjaws.

7.3.4.3The lengthof the exposedconductorbetweeneachgrippingmeansandeachconnectorshallnot

be lessthanthatgivenin Table8.
\- 7.g.4.4Thetensilestrengthshallbe determined as the maximumloadthatcan be applied.Thisload
for Class1 connectorsand 5olofor Class2 and3 connectorswith
shallbe measuredto an accuracyol 1o/o
instruments
calibratedaccordingto ASTME4. The modeof failureshallbe recorded.

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
whichruptureor permanent distortionof anyconnectorcomponent occursthatimpairsits proper
functioning
on anyof the conductorcombinations was designed.
for whichthe connector

7.5 Conductordamagetest
7.5,1 The conductor damagetestfor the tap connector shallbe performed on maximurn-run and
minimunrrunconductors of eachtypefor whichthe connectoris designed.In all tests,the maximum-
diametertap conductorof the hardesttemperfor whichthe connectoris designedshallbe used.

7.5.2 A tap connector shallbe installedon a runconductor whoselengthbetweengrippingmeansis as

of its ratedstrengthas determinedin
specifiedas Class1 in Table8, and is undera tensileloadof 20o/o

\-.

@Copyright2005by the NationalElectricalManufac{urers

Association 15
ANS|C119.+2W

4.4.2. Relaxation The conductorshallthenbe

of the loadshallnotoccurduringconnectorinstallation.
stressedto the breaking point.

Table 8 - Length of exposedconductor

Connector Description Length

Class
lnches Meters

Class1 Intendedfor singlemetalorsinglealloy 24 0.61

(a) conductors with 19 strandsor less.
(b) Intendedfor singlemetalor singlealloy 1M* 3,66*
conductorswithmorethan 19 strands
(c) Intendedfor multiplemetalormultiplealloy 144' 3.66*
conductors
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
datato supportconformance
Thetestreportshallincludethe necessary to the
or nonconformance
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

ClassAA,A, B, C
Electrical:
Mechanical: Class1,2, 3
Method:CCT,CCST

Narneand addressof the test facilityand the namesof the techniciansperformingthe test

All optionsusedin performanceof the testincludingthe mountingmethod(drilledor surfacemounted)of

the thermocouples (diagrams
or photographs of the testsetupare desirable)

Otherpertinentinformation,suchas installationdetailsnot specificallydefinedor requiredin this standard

Certification(if required)

16 Association
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