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

trrr*gl

lr t0llt

ErctEnric oocurtlll

trlt lt lm$sbi 0t ilEmA

tG..tn ttl
Urar ft*t

\,

ffi

ANS! C119.4-2004

American
National
Standard
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
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

@Copyright2005by the NationalElectricalManufac{urers

Association

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

Tensile
load

Tightening
torque

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

Conductor
lengthsfor cunentcycletests..

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

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

6
7
8

Resistance
andtemperature
measurement
intervals
Length
of exposed
conductor

@copyright2005by the NationatElectricalManufacturers

Association

........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

@Copyright2005by the NationalElectricalManufac{urers

Association

ANS|C119.+2004
DavidWest

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:

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

@Copyright2005by the NationalElectricalManuf;acturers

Association

vtl

AMERICANNATIONALSTANDARD

ANS| C119.4-2004

\,

Gonnectors for Use BetweenAl umi num-to-Alumi num

or Aluminum-toopper Bare OverheadGonductors

.
'

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.

v
@Copyright2005by the NationalElectricalManufacturers
Association

ANSfCl19.4-20U

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

@Copyright2005by the NationalElectricalManufacturers

Association

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

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

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

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.

Association
@Copyright2005by the NationalElectricalManufac{urers

\,

ANS|C119.+200/.

v
I

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

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.

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

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.

Test Procedures,General

5.1

Test connectors

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

5.1.2 Familysampleset

(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

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
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.

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 "cunentFF"cycle. Comparative
testinghasdemonstrated
thatthe CCST
methodwill provideessentiallythe sameperformancetest resultsas the traditionalcurrentcycletest (CCT)in fanriertest cycles.

@Copyright2005by the NationalElectricalManufac{urers

Association

ANS|C119.+200/.

6.2

Test assembly

\,

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.

sI
I

i
i

'

Association
@copyright2005by the NationalElectricalManufacturers

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.

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.

\/

Association
@Copyright2005by the NationalElectricalManuf;ac{urers

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)

90

95

125

130

170

180

200

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

Association
Manufac{urers
2005by the NationalElectrical
@Copyright

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

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.

@Copyright2005by the NationalElectricalManufacturers

Association

11

ANS|C119.+200/

Table 6 - Current cycle periods for control conductorc

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 CCSTcurrentcycleFF 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.

12

@Copyright2005by the NationalElectricalManufadurersAssociation

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:
{

cr= 4 X 1O{/"Cfor copperandACSR

cr= 3.6X 1O/'Cfor aluminum

6.10.2 Temperaturemeasurements

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

@Copyright2005 by the NationalElectricalManufacturers

Association

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.

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.

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

Association
Manufacturers
2005by the NationalElectrical
@Copyright

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
\-.

Association
@Copyright2005by the NationalElectricalManufac{urers

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.

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

Association
@Copyright2005by the NationalElectricalManufac{urers