ENGINEERING TEST REPORT

GelPort Sealed Bus Connector

to accommodate
500Kcmil conductor

P/N GB-500-3P-CONNSCREW

502-47308 (I)
REV. 0

ACT No.: 3843

Date: 25TH April 2006
Classification: II
Prepared By: W. Holness
Distribution: B. Johnson
P. Carey

CONTROLLED DOCUMENT
This report is a controlled document
per Tyco specification 102-21.
It is subject to change and Tyco Electronics Canada Ltd.
Document Control should be contacted
for the latest revision.

Test Laboratory
Markham, Ontario
 502-47308 (I) Rev. 0

Table of Contents

Page

1. Introduction 1
1.1 Purpose 1
1.2 Scope 1
1.3 Conclusion 1
1.4 Product Description 2
1.5 Test Specimens 2
1.6 Test Sequence 2

2. Summary of Testing 3
2.1 Examination of Product 3
2.2 Current Cycling (Temperature) 3
2.3 Current Cycling (Resistance) 3
2.4 Mechanical Pull Out Test 3

3. Test Methods 4
3.1 Examination of Product 4
3.2 Current Cycling (Temperature) 4
3.3 Current Cycling (Resistance) 4
3.4 Mechanical Pull Out Test 5

4. Validation 6

5. Table of Mechanical Pull Out (Table 2) 7

6. Representative photographs of GelPort Sealed Bus Connector,

P/N GB-500-3P-CONNSCREW (Figs. 1 - 12) 8 –17

CONTROLLED DOCUMENT
This report is a controlled document
per Tyco specification 102-21.
It is subject to change and Tyco Electronics Canada Ltd.
Document Control should be contacted
for the latest revision
 502-47308 (I) Rev. 0

Engineering Test Report

GelPort Sealed Bus Connector

1. Introduction

1.1 Purpose

Testing was performed on the GelPort Sealed Bus Connector (p/n GB-500-3P-CONNSCREW) to
determine its compliance to ANSI C119.4 – 2004, Connectors for Use Between Aluminum to
Aluminum or Aluminum to Copper Bare Overhead Connectors, Class A (heavy duty), current
cycling test using 500 Kcmil Copper conductor (37 strand) and 500 Kcmil AAC conductor (37
strand).
Testing was also performed on (p/n GB-500-3P-CONNSCREW) to determine its
compliance to the Class 3 (minimum tension) mechanical Pull Out test in accordance with ANSI
C119.4 – 2004, again using 500 Kcmil Copper conductor (37 strand) and 500 Kcmil AAC
conductor (37 strand).

1.2 Scope

This report covers the electrical and mechanical performance of the GelPort Sealed Bus
Connector (p/n GB-500-3P-CONNSCREW).
The testing was performed between 4th January 2006 to 22nd March 2006.

1.3 Conclusion

The GelPort Sealed Bus Connector (p/n GB-500-3P-CONNSCREW) complied with the
requirements of ANSI C119.4 – 2004, Connectors for Use Between Aluminum to Aluminum or
Aluminum to Copper Bare Overhead Connectors, Class A (heavy duty), current cycling test using
either 500 Kcmil Copper conductor (37 strand) or 500 Kcmil AAC aluminum conductor (37
strand).
GelPort Sealed Bus Connector (p/n GB-500-3P-CONNSCREW) , also complied with the
Class 3 (minimum tension), mechanical Pull Out requirements in accordance with ANSI C119.4-
2004, using both 500 Kcmil Copper conductor (37 strand) and 500 Kcmil AAC conductor (37
strand).

CONTROLLED DOCUMENT
This report is a controlled document
per Tyco specification 102-21.
It is subject to change and Tyco Electronics Canada Ltd.
Document Control should be contacted
for the latest revision
Page 1
 502-47308 (I) Rev. 0

1.4 Product Description

The GelPort Sealed Bus Connector is designed to provide a sealed secondary connection where a
feed wire may be terminated in one port and provide from one to 7 tap connections to be made
from the same connector. The product use range is for #14-350 & #2-500 aluminum connections.
The product consists of an aluminum bus bar with single set screw at each port to provide
connections. The bus bar is sealed inside a rigid plastic housing which is gel sealed. The
application is commonly used for residential power distribution and will typically be installed in
hand holes. The product is also capable of being installed in overhead or UV exposed
applications as well.

1.5 Test Specimens

The following part numbers and quantities were used:

TABLE 1

GelPort Sealed Bus Installation

Group Quantity Conductor Combination
Connector p/n Torque (in lbs)
GB-500-3P- 500 Kcmil Copper (37 strand) –
1 4 350
CONNSCREW 500 Kcmil Copper (37 strand)
GB-500-3P- 500 Kcmil AAC (37 strand) –
2 4 350
CONNSCREW 500 Kcmil AAC (37 strand)
GB-500-3P- 350
3 3 500 Kcmil AAC (37 strand)
CONNSCREW
GB-500-3P- 350
4 3 500 Kcmil Copper (37 strand)
CONNSCREW

1.6 Test Sequence

TEST OR EXAMINATION TEST GROUPS

1 2 3 4
Examination of Product 1, 4 1, 4 1, 3 1, 3
Termination Resistance –
2 2
Specified Current
Current Cycling 3 3
Mechanical Pull Out 2 2

Note: Number indicates sequence in which tests were performed.

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Document Control should be contacted
for the latest revision
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2. Summary of Testing

2.1 Examination of Product

All materials submitted for testing are representative of production parts and are standard
specimens, examined and supplied by Power Cable Accessories, Energy Division, Tyco
Electronics, Fuquay-Varina.

2.2 Current Cycling (Temperature) – (Groups 1 & 2)

There was no evidence of physical damage to the test specimens after 500 cycles of current
cycling. The temperatures of the specimens did not exceed the temperature of the control
conductor and the temperature difference between the control conductor and the specimens was
stable between the 25th cycle and the 500th cycle. Stability was achieved when the temperature
difference between the control conductor and the specimen, including allowance for measurement
error, is not more than 10°C from the average of the measured temperature differences.

2.3 Current Cycling (Resistance) – (Groups 1 & 2)

All termination resistance measurements taken initially, during current cycling and after current
cycling met the specification requirement by not varying more than +/- 5% from the average of
the measured values taken between the 25th to the 500th cycle interval.
All measurements were corrected to the resistance at 20°C.

2.4 Mechanical Pull Out – (Groups 3 & 4)

All mechanical pull out values met or exceeded the specification requirements of 5% of the rated
conductor strength for a class 3 tension or table 2 of ANSI C119.4 - 2004.
Refer to table 2 for full test results.

CONTROLLED DOCUMENT
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for the latest revision

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3. Test Methods

3.1 Examination of Product

The specimen’s were supplied for testing by Power Cable Accessories, Energy Division, Tyco
Electronics, Fuquay-Varina.
They were examined visually and functionally.

3.2 Current Cycling (Temperature) – (Groups 1 & 2)

Eight GelPort Sealed Bus Connectors (p/n GB-500-3P-CONNSCREW) were supplied for testing.
They were installed in (2) series circuit loops using approximately 24” lengths of bare 500 Kcmil
Copper conductor (37 strand) or bare 500 Kcmil AAC conductor (37 strand) between any
equalization point and connector, (refer figs. 1 & 4).
The control conductor was of the same size, but was 48” in length. Prior to insertion into
the connector, the end of each length of conductor was prepared by brushing with a dry stainless
steel brush to remove surface oxidation (refer figs. 2 & 5).
Each connector was tightened to the minimum torque requirement supplied for the 500
Kcmil conductor (refer table 1). Thermocouples were applied to each connector and in the middle
of the control conductor. Voltdrop leads in order to determine the resistances were applied to each
connector and to each equalizer either side of each connector.
Each test loop was energized with a current of approximately 828 amps (500 Cu.) or 683
amps (500 AAC), which raised the temperature of the control conductor to 100 – 105°C above
the ambient temperature.
The cycle time throughout the test was 1.5 hours ‘CURRENT ON’ and 1.5 hours
‘CURRENT OFF’. The connectors were subjected to a total of 500 cycles. The temperature of the
control conductor and the connectors were taken during the cycles preceding the termination
resistance measurements.

3.3 Current Cycling (Resistance) – (Groups 1 & 2)

Termination resistance was measured using a test current of approximately 19 amperes dc.
Measurements were taken initially and at the following cycles 25, 50, 75, 100, 125, 165, 205,
250, 325, 405 and 500 +/- 5 cycles.

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It is subject to change and Tyco Electronics Canada Ltd.
Document Control should be contacted
for the latest revision
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3.4 Mechanical Pull Out – (Groups 3 & 4)

A 24” length of 500 Kcmil conductor (37 strand) was installed in one of the cable ports of the
GelPort Sealed Bus Connectors, p/n GB-500-3P-CONNSCREW.
The head of the bolt was tightened to the value in table 1 (minimum torque) and the free end of
each connector / conductor combination was held in the lower jaws of an Instron tensile machine
(model # 4206-006). A fixture incorporating the rest of the connector / conductor combination
was held in the upper jaws of the machine (refer figs. 7 & 10).
An axial load was applied to the test specimen at a rate of 0.5” per minute, until either the
conductor pulled out or a broken wire strand ends the test.
This process was repeated until a total of 6 specimens had been tested, 3 using 500 Kcmil
Copper and 3 using 500 Kcmil AAC (refer figs. 8 – 9 & 11 - 12).

CONTROLLED DOCUMENT
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It is subject to change and Tyco Electronics Canada Ltd.
Document Control should be contacted
for the latest revision
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Table 2 - Mechanical Pull Out Values (lbs) GB-500-3P-CONNSCREW

Test GelPort Initial Peak

Group Sealed Bus Torque Load Mode of Failure Comments
# Conn. # (in/lbs) (lbs)
500 Kcmil AAC (37
Wire slip through
1 350 >445.5 strand) wire installed in
connector, ends test
connector
500 Kcmil AAC (37
Wire slip through
3 2 350 >455.5 strand) wire installed in
connector, ends test
connector
500 Kcmil AAC (37
Wire slip through
3 350 >455.5 strand) wire installed in
connector, ends test
connector
Class 3 Requirement, 5% RBS Rated Breaking Strength of 500 Kcmil AAC wire
455.5
or Table 2, ANSI C119.4 - 2003 = 9,110 lbs
500 Kcmil Copper (37
Wire slip through
4 350 >762 strand) wire installed in
connector, ends test
connector
500 Kcmil Copper (37
Wire slip through
4 5 350 >762 strand) wire installed in
connector, ends test
connector
500 Kcmil Copper (37
Wire slip through
6 350 >762 strand) wire installed in
connector, ends test
connector
Class 3 Requirement, 5% RBS Rated Breaking Strength of 500 Kcmil Copper
762
or Table 2, ANSI C119.4 - 2003 wire = 15,240 lbs

Note:- Each pull out test was performed on a previously untested cable port.

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Fig. 1

GB-500-3P-CONNSCREW

Representative photograph of GelPort Sealed Bus Connectors (p/n GB-500-3P-CONNSCREW)

installed on 500 Kcmil AAC (37 strand) aluminum conductor, during Current Cycling Test to
ANSI C119.4 – 2004, Class A

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Fig. 2

Voltdrop lead used for

resistance calculation

Thermocouple used
for temperature
measurement

Representative Close-Up photograph of GelPort Sealed Bus Connector (p/n GB-500-3P-

CONNSCREW) installed on 500 Kcmil AAC (37 strand) aluminum conductor, before
Current Cycling Test to ANSI C119.4 – 2004, Class A.

CONTROLLED DOCUMENT
This report is a controlled document
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It is subject to change and Tyco Electronics Canada Ltd.
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for the latest revision

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Fig. 3

Thermocouple used
for temperature
measurement

Voltdrop lead used for

resistance calculation

Representative Close-Up photograph of GelPort Sealed Bus Connector (p/n GB-500-3P-

CONNSCREW) installed on 500 Kcmil AAC (37 strand) aluminum conductor, after
Current Cycling Test to ANSI C119.4 – 2004, Class A.

CONTROLLED DOCUMENT
This report is a controlled document
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It is subject to change and Tyco Electronics Canada Ltd.
Document Control should be contacted
for the latest revision

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Fig. 4

GB-500-3P-CONNSCREW

Representative photograph of GelPort Sealed Bus Connectors (p/n GB-500-3P-CONNSCREW)

installed on 500 Kcmil Copper (37 strand) conductor, during Current Cycling Test to ANSI
C119.4 – 2004, Class A

CONTROLLED DOCUMENT
This report is a controlled document
per Tyco specification 102-21.
It is subject to change and Tyco Electronics Canada Ltd.
Document Control should be contacted
for the latest revision

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 502-47308 (I) Rev. 0

Fig. 5

Thermocouple used
for temperature
measurement

Voltdrop lead used for

resistance calculation

Representative Close-Up photograph of GelPort Sealed Bus Connector (p/n GB-500-3P-

CONNSCREW) installed on 500 Kcmil Copper (37 strand) conductor, before Current
Cycling Test to ANSI C119.4 – 2004, Class A.

CONTROLLED DOCUMENT
This report is a controlled document
per Tyco specification 102-21.
It is subject to change and Tyco Electronics Canada Ltd.
Document Control should be contacted
for the latest revision

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 502-47308 (I) Rev. 0

Fig. 6

Thermocouple used
for temperature
measurement

Voltdrop lead used for

resistance calculation

Representative Close-Up photograph of GelPort Sealed Bus Connector (p/n GB-500-3P-

CONNSCREW) installed on 500 Kcmil Copper (37 strand) conductor, after Current
Cycling Test to ANSI C119.4 – 2004, Class A.

CONTROLLED DOCUMENT
This report is a controlled document
per Tyco specification 102-21.
It is subject to change and Tyco Electronics Canada Ltd.
Document Control should be contacted
for the latest revision

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Fig. 7

Upper Jaws

Test Fixture GB-500-3P-CONNSCREW

Lower Jaws

Representative photograph of GelPort Sealed Bus Connector (p/n GB-500-3P-

CONNSCREW) and 500 Kcmil AAC (37 strand) aluminum conductor, installed in Instron
Tensile machine during Mechanical Pull Out Test.

CONTROLLED DOCUMENT
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It is subject to change and Tyco Electronics Canada Ltd.
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Fig. 8

BEFORE

Representative Close-Up photographs of GelPort Sealed Bus Connector (p/n GB-500-3P-

CONNSCREW) installed on 500 Kcmil AAC (37 strand) aluminum conductor during the
Mechanical Pull Out Test.
Fig. 9

AFTER

Page 15
 502-47308 (I) Rev. 0

Fig. 10

Upper Jaws

GB-500-3P-CONNSCREW
Test Fixture

Lower Jaws

Representative photograph of GelPort Sealed Bus Connector (p/n GB-500-3P-

CONNSCREW) and 500 Kcmil Copper (37 strand) conductor, installed in Instron Tensile
machine during Mechanical Pull Out Test.

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Fig. 11

BEFORE

Representative Close-Up photographs of GelPort Sealed Bus Connector (p/n GB-500-3P-

CONNSCREW) installed on 500 Kcmil Copper (37 strand) conductor during the
Mechanical Pull Out Test.
Fig. 12

AFTER

Page 17