R E F EREN CE www.hubbell.com/burndy | O-3 Introduction - Basic Electrical Connections Principles Contact Compounds: Petrolatum or No-Oxid are good contact surface compounds for aluminum, but BURNDY® PENETROX™ A, a petroleum type compound containing zinc dust, has the additional advantage of assisting in the breaking down of the contact resistance. How this is accomplished is not certain, but it appears that the zinc particles of PENETROX™ A probably act as current bridges in the breaks in the oxide film. For more complete information about the PENETROX™ line of compounds, refer to the Accessories section of this catalog. Interstrand Resistance: The high contact resistance due to the oxide on the strands of an aluminum cable may be responsible for a poor distribution of current among the strands on the cable. Thus, the outer strands may carry much more than their share of the current and overheating of the cable may result. Tests have shown that even on new cable this effect of interstrand resistance can be considerable unless a good contact compound is used. The clamping action tends to break down the oxide and force the compound between the strands. This is particularly true of compression connectors due to the very high unit pressures developed. The most effective way to break down interstrand resistance of aluminum cable is to use compression connectors filled with a compound having zinc particles. Then, when the end of the cable is inserted in the connector, the compound is forced between the strands where it very effectively breaks down the interstrand resistance upon applicaton of the compressive force. Plating Aluminum: Plating the contact surfaces of aluminum connectors will prevent the formation of aluminum oxide. Electro-tin, cadmium and zinc platings have been used for this purpose. However, the use of a plated aluminum connector does not make it less necessary to scratch brush the aluminum conductor, nor does it reduce the need for a good contact compound. Additional problems are introduced due to the plating on aluminum which render it of very doubtful value over the proper use of base aluminum. This will be more fully discussed later. Corrosion The electrical conductivity and mechanical strength of an electrical connection must remain stable under the deteriorating influences of the environment. This deterioration is corrosion. It is the electrolytic action of moisture and other elements of the atmosphere in conjunction with the metals of the connection. If the conductors and connectors are of copper or a corrosion resistant copper alloy, corrosion is usually a minor factor. However, it is a very vital factor if aluminum is involved. If moisture can be kept away from the connection, corrosion will not be a factor. The electrical connection of a high voltage splice on insulated cable is generally free from corrosion since the taping may be used to avoid corrosion on bare cable, provided it excludes moisture. It is difficult to get a good tape seal to the conductor itself, especially on stranded cable. If moisture does penetrate the taping, it will not dry out as readily as if the joint were untaped. Various plastic materials are available today for covering low voltage connections or for bare conductor connections on high voltage. Unless such coverings are completely moisture-proof, it is better to rely on installation with a good contact compound, using a connector designed to resist corrosion. Galvanic Action: Whenever dissimilar metals are in the presence of an electrolyte, a difference in electric potential is developed. One metal becomes the cathode and receives a positive charge. The other becomes the anode and receives a negative charge. When these metals are in contact, an electrical current will flow, as in the case of any short-circuited electric cell. This electrolytic action causes an attack of the anodic metal, leaving the cathodic metal unharmed. The extent of the attack is proportional to the strength of the electrolytic current, which in turn is proportional to the electric potential difference developed. The magnitude of the potential difference generated between two dissimilar metals can be seen by the position of these metals in the electrolytic series. Figure 3 is such a series. When two metals are in contact in an electrolyte, the one higher up in this series is the anode, the corroded metal, while the one lower is the cathode, the protected metal. The further apart the metals are in this series, the greater the electrolytic potential difference, and the greater the attack to the anodic metal. Note that copper and aluminum are quite far apart in the series, copper being cathodic and aluminum anodic. Hence, when aluminum and copper are in contact in an electrolyte, the aluminum can be expected to be severely attacked. Crevice Corrosion: Electrolytic attack can also occur between like metals due to a phenomenon known as oxygen concentration cell or crevice corrosion. Since oxygen is necessary for corrosive action, a variation in the concentration of oxygen where a metal is exposed to an electrolyte will generate a difference of potential, and cause a corrosive attack in the oxygen starved area. Thus, since an electrolyte in a deep crevice is freely exposed to the air at the outside, the concentration of oxygen will be greatest at the mouth of the crevice. Then corrosion can be expected to occur in the crevice remote from the surface. Crevice corrosion can be prevented if the crevice is filled with a compound to exclude moisture. Thus, within the contact groove of an aluminum connector containing an aluminum conductor, there will be numerous crevices in which corrosion will take place unless a good connector compound is applied during installation. Copper, being a more noble metal, appears to be much less subject to crevice corrosion. Corrosion Testing: The effectiveness of an electrical connection to resist corrosion can be tested in the laboratory under conditions designed to greatly accelerate the natural corrosive conditions of actual service. The most widely accepted means is the standard salt spray chamber. In this chamber the specimens are placed in a salt fog made by atomizing a 20% salt solution at 100˚ F. BURNDY, as well as other manufacturers and utility companies, have done a great deal of testing and a considerable area of agreement has been reached. There are, however, minor differences in recommended practices. The problem is concerned with aluminum and aluminum to copper connections since the effect of corrosion on copper to copper connections is far less serious. Let us study the recommended practices. Aluminum to Aluminum Connections: For joining aluminum to aluminum conductors, there is little disagreement that an aluminum bodied connector is the proper choice, since this obviously elimates the galvanic corrosion of dissimilar metals. However, even in this case, care must be taken to prevent crevice corrosion and to select an alloy of aluminum for the connector body that is free from cracking due to stress corrosion. Aluminum to Copper Connections: Similarly, for joining aluminum to copper conductors, an aluminum bodied connector is the best choice since it prevents galvanic corrosion of the aluminum conductor, the most vulnerable element to attack in the connection. Realizing this, BURNDY initiated a research program aimed at finding the best way to make an aluminum connector suitable for joining aluminum to copper conductors. This led to the evolution of the “Massive Anode Principle” of connector design for joining conductors of dissimilar metal. On the basis of this principle, properly designed, all- aluminum connectors became available for universal use in joining aluminum to aluminum or aluminum to copper conductors. Massive Anode Principle: By making the aluminum connector massive in comparison to the copper conductor, when the copper conductor emerges from the connector, the electrolytic current density over the exposed face of the aluminum connector is greatly reduced. This is schematically represented in Figure 4. Since the rate of corrosion is directly related to the current density on the surface of the anodic material, the relatively large face of the aluminum connector will suffer only minor attack. Introduction - Basic Electrical Connection Principles (continued)
