a

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor Catalog

Substation Products

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor Catalog

ACASS0602

ENGINEERED

Performance

Motion Control Accessories Spacers Vibration Dampers Spacer-Dampers Substation Accessories Bolted and Welded A-Frame Fabrication Tubular and Extruded Bus Conductors Transmission Accessories Compression Accessories Quick Compress Accessories Hi Temp Compression Accessories Distribution Accessories Parallel Groove Clamps Compounds Electrical Joint Compound Alnox Filler Compound Wire Products Alumoweld Copper Clad Steel AWAC Engineering Software Sag10 Vibration Analysis Fiber Optic Accessories Optical Ground Wire Accessories ADSS Accessories Skywrap Accessories

In 1897, Alcoa sold the rst aluminum for a current-carrying application. That sale was the beginning of a relationship between Alcoa and the electrical industry that has prevailed for more than a century. Today, Alcoa Conductor Accessories (ACA), a division of AFL Telecommunications, is one of the worlds foremost suppliers of aluminum conductor accessories to the electric utility industry. Yet, we are more than simply a manufacturer of accessory products. We offer a depth of engineering, production, training and testing services not available from any other source, at any price. With ACA, not only will you get a quality product, you get the performance, reliability and know-how that makes it all work.Theres only one source you need for your transmission, distribution and ber optic accesory needs.

Alcoa Conductor Accessories

A division of AFL Telecommunications

P.O. Box 3127 Spartanburg, SC 29304-3127 (864) 433-0333

1-800-866-7385
www.AFLtele.com/aca

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

SS-6 Table of Contents

Tab and Page Benets of Aluminum Bus Conductor ............................... SS-6 2 Alloys and Tempers ........................................................... SS-6 2 Special Finishes and Packaging ....................................... SS-6 2 Factors to Consider When Selecting a Bus Conductor ..... SS-6 2 Seamless Bus Pipe ........................................................... SS-6 3 Seamless Bus Tube ........................................................ SS-6 5 Rectangular Bar ................................................................ SS-6 7 Integral Web Bus Conductor (IWBC)............................... SS-6 10 Channel Bus Conductor .................................................. SS-6 12 Square Bus Tube ............................................................ SS-6 14 Integral Web (IWBC) Universal Angle Bus Conductor (UABC) ........................ SS-6 16 Mechanical Properties of Aluminum Bus Conductors .... SS-6 18 Bending and Forming ..................................................... SS-6 19 Deection Values ............................................................ SS-6 20 Welding Aluminum Bus to Aluminum Connectors ........... SS-6 22 Frequently Asked Questions ........................................... SS-6 24 Bus Pipe and Tube

Square Bus Tube

Channel Bus

Angle (UABC) Bus

Bus Bar

SS-6 1

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

Benets of Aluminum Bus Conductor

Only the weight of copper Highly corrosion resistant Dissipates heat rapidly and evenly Very strong yet lightweight Easy to fabricate Conducts equivalent loads of electric power with one half as much material weight as copper

Today, aluminum is one of the most widely specied conductive materials used in the manufacture and construction of electrical power distribution components and equipment. Typical applications presently using aluminum conductors include bus duct, bus bar, panel boards, switchgear, isolated phase bus and a host of other similarly purposed products installed virtually everywhere from electric utility switchyards to substations construction all over the world.

6063-T6, 6061-T6, 6101-T6, 6101-T61, and 6101-T63. For other alloys or tempers, please contact your ACA Sales Representative. Special Finishes and Packaging ACA aluminum bus conductor is manufactured with an EHV (Extra-High Voltage) nish and EHV packaged. EHV packaging consists of inter-leafed paper and cardboard boxed. Factors to Consider When Selecting a Bus Conductor There are many considerations when selecting a bus conductor shape for a particular installation. Examples are: D-C or A-C current Ampacity required Frequency Operating voltage Allowable voltage drop Maximum possible short circuit currents Available space Weather conidtions Taps and connections required Lengths Bus Conductor is sold in various lengths ranging from 10 feet to 40 feet. Longer lengths are available in various sizes. Contact your ACA Sales Representative for more information.

Alloys and Tempers The most commonly used alloys are 6063, 6061, and 6101. Alloy 6063 has been widely used for outdoor high voltage substation bus because of its excellent mechanical and electrical properties. Where high strength and lower conductivity is called for, alloy 6061 bus is used. Where high conductivity is required, with a minimum sacrice in mechanical properties, alloy 6101 is used. Alcoa Conductor Accessories (ACA) aluminum bus conductors are manufactured to meet appropriate ASTM specications. These include B241-00 - Aluminum Alloy Seamless Pipe and Tube for Alloys 6063 and 6061; and B-317-00 - Aluminum Alloy Extruded Bar, Rod, Pipe and Structural Shapes for Electrical Purposes for Alloy 6101. The tempering process is an application that hardens or strengthens the metal by applying heat and/or cooling the metal. The basic temper consists of a letter followed by one or more numbers. The most common tempers are T6, T61, and T63. T6 is solution heat treated, and artically aged to maximum mechanical property levels. T61 is an overaged temper with higher conductivity, but lower mechanical properties than T6. T63 is an in-between temper with higher conductivity than T6, but less than T61. The most common alloy and temper combinations are

SS-6 2

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

Seamless Bus Pipe

Seamless bus pipe is an extruded tubular product used to convey electricity. It is manufactured to a nominal, not actual, inside diameter. The wall thickness is described by a schedule. The schedules are determined by the American Standards Association. Seamless bus pipe is generally made of 6063-T6 alloy in ANSI Schedule 40 pipe because of its excellent mechanical and electrical properties. 6061T6 alloy tubular bus is used where high strength and lower conductivity are required.
Note: For seamless bus pipe over 6 inches, contact the ACA Commercial Team.

Schedule 40
Nominal Size In SCH 40 1 1 1/4 1 1/2 2 2 1/2 3 3 1/2 4 4 1/2 5 6 Outside Diameter of Tube In A 1.315 1.660 1.900 2.375 2.875 3.500 4.000 4.500 5.001 5.563 6.625 Wall Thickness In B 0.133 0.140 0.145 0.154 0.203 0.216 0.226 0.237 0.247 0.258 0.280 0.4939 0.6685 0.7995 1.0750 1.7040 2.2280 2.6800 3.1740 3.6880 4.3000 5.5810 0.581 0.786 0.940 1.264 2.004 2.621 3.151 3.733 4.337 5.057 6.564 Area Weight Nominal Size In SCH 80 1 1 1/4 1 1/2 2 2 1/2 3 3 1/2 4 4 1/2 5 6

Schedule 80
Outside Diameter of Tube In A 1.315 1.660 1.900 2.375 2.875 3.500 4.000 4.500 5.000 5.563 6.625 Wall Thickness In B 0.179 0.191 0.200 0.218 0.276 0.300 0.318 0.337 0.355 0.375 0.432 0.6388 0.8815 1.0680 1.4770 2.2540 3.0160 3.6780 4.4070 5.1800 6.1120 8.4050 0.751 1.037 1.256 1.737 2.650 3.547 4.326 5.183 6.092 7.188 9.884 Area Weight

Sq In

lb/ft

Sq In

lb/ft

Ordering Instructions:
Step 1: Choose Nominal Size Nominal Size 1 1 1/4 1 1/2 2 2 1/2 3 3 1/2 4 4 1/2 5 6 Size Code 100 125 150 200 250 300 350 400 450 500 600 Size Code Step 5: Build Catalog Number Step 2: Choose Schedule Schedule Number SCH 40 SCH 80 Schedule Code S40 S80 Step 3: Choose Alloy Alloy Number 6061 6063 6101 Alloy Code X Y Z Step 4: Choose Temper Temper T6 T61 T63 Temper Code T6 T61 T63

Schedule Code

Alloy Code

Temper

Example: To order 2 1/2 inch Schedule 40 6101 T-61 Alloy Bus Pipe 250

S40

T61

Completed Catalog Number is 250S40ZT61.

SS-6 3

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

Physical and Electrical Properties of Aluminum

Standard Pipe-Size Conductors at Typical Conductivities

6063-T6 A Nominal Size In B Area Sq In Weight Inductive DC reactance 1 ft spacing Resistance at 20oC 60 Hz microhms/ microhm/ft ft AC Resistance at 70oC 60 Hz microhms/ ft Current Ratings Amp at 60 Hz (1) (2) (3) (4) Outdoor 681 859 984 1234 1663 2040 2347 2664 2984 3348 4064 774 985 1137 1446 1907 2363 2735 3118 3505 3949 4891 DC Resistance at 20oC microhms/ ft

6061-T6 AC Resistance at 70oC 60 Hz microhms/ft Current Ratings Amp at 60 Hz (1) (2) (3) (4) Outdoor 622 705 900 1128 1520 1865 2145 2436 2728 3063 3719 707 901 1039 1322 1746 2199 2507 2862 3221 3631 4532

Outside Diameter of Tube In 1.315 1.660 1.900 2.375 2.875 3.500 4.000 4.500 5.001 5.563 6.625 1.315 1.660 1.900 2.375 2.875 3.500 4.000 4.500 5.000 5.563 6.625

Wall Thickness In

60 Hz Rac/Rac at 70oC

61 Hz Rac/Rac at 70oC

Schedule 40 Pipe 1 1 1/4 1 1/2 2 2 1/2 3 3 1/2 4 4 1/2 5 6 1 1 1/4 1 1/2 2 2 1/2 3 3 1/2 4 4 1/2 5 6 0.133 0.140 0.145 0.154 0.203 0.216 0.226 0.237 0.247 0.258 0.280 0.179 0.191 0.200 0.218 0.276 0.300 0.318 0.337 0.355 0.375 0.432 0.494 0.669 0.800 1.075 1.704 2.228 2.680 3.174 3.688 4.300 5.581 0.639 0.882 1.068 1.477 2.254 3.016 3.678 4.407 5.180 6.112 8.405 0.581 0.786 0.940 1.264 2.004 2.621 3.151 3.733 4.337 5.057 6.564 0.751 1.037 1.256 1.737 2.650 3.547 4.326 5.183 6.092 7.188 9.884 68.24 62.68 59.45 54.15 49.85 45.19 42.05 39.28 36.81 34.31 30.23 68.81 63.14 59.89 54.56 50.23 45.55 42.39 39.61 37.13 34.63 30.58 31.120 22.990 19.220 14.300 9.019 6.897 5.736 4.842 4.167 3.574 2.754 24.060 17.440 14.390 10.400 6.820 5.096 4.178 3.487 2.967 2.515 1.829 1.00039 1.00050 1.00064 1.00082 1.00220 1.00300 1.00380 1.00470 1.00570 1.00680 1.00950 1.00100 1.00140 1.00200 1.00280 1.00720 1.01030 1.01380 1.01710 1.02100 1.02600 1.04570 36.580 27.030 22.600 16.820 10.620 8.126 6.761 5.712 4.920 4.224 3.263 28.300 20.520 16.940 12.260 8.071 6.050 4.972 4.168 3.559 3.032 2.247 38.360 28.340 23.690 17.630 11.170 8.500 7.070 5.968 5.136 4.406 3.394 29.650 21.490 17.730 12.820 8.406 6.281 5.150 4.298 3.657 3.099 2.254 1.00032 1.00039 1.00046 1.00055 1.00150 1.00180 1.00220 1.00270 1.00330 1.00400 1.00540 1.00075 1.00105 1.00150 1.00210 1.00390 1.00490 1.00750 1.00950 1.01160 1.01650 1.02120 43.820 32.370 27.070 20.140 12.710 9.725 8.091 6.834 5.885 5.051 3.897 33.840 24.570 20.280 14.670 9.647 7.225 5.935 4.965 4.236 3.604 2.656

Schedule 80 Pipe

Notes 1. Current ratings listed in the Tables are based on 30oC temperature rise over 40oC ambient horizontally mounted conductors, with spacing sufcient to eliminate proximity effects, generally assumed not to be signicant if spacing is 18 in. or over. Conduction of heat by supporting structures and taps can appreciably affect the ratings. 2. Conductors with a 2ft/sec crosswind. Nominal oxidized surface (e=0.50) 3. Current Ratings for direct current are close to those of alternating current for all except the larger sizes; and for them, the increase for dc bus is about 1.5 percent. 4. NEMA Standard SG1-3.02 (7/13/60) lists current rating for tubes of 57%-61% IACS conductivity, but without stated emissivity factors. However, even after adjustment for the 53% IACS conductivity of 6063-T6 alloy (and 43% for 6061-T6 alloy), the ratings differ somewhat from those of this table.

SS-6 4

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

Seamless Bus Tube

Seamless bus tube is a round, hollow material manufactured to a specic outside diameter (O.D.) and wall thickness. It is produced to meet specic end user requirements. Tubing is described by the actual outside diameter and wall thickness, i.e. 8 O.D. x 0.500 Wall aluminum tubing. Outdoor tubular bus is generally made of 6063-T6 alloy because of its excellent mechanical and electrical properties and is readily availability. 6061T6 tubular conductor is used where very high strength and lower conductivity is required.
Note: For seamless bus tube sizes not listed, contact the ACA Commercial Team.

Outside Diameter of Tube In A 8 8 8 8 9 9 9 9

Wall Thickness In B 0.250 0.375 0.500 0.625 0.250 0.375 0.500 0.625

Area

Weight

Outside Diameter of Tube In A 10 10 10 10 12 12 12 12

Wall Thickness In B 0.312 0.375 0.500 0.625 0.312 0.375 0.500 0.625

Area

Weight

Sq In 6.09 8.98 11.78 14.48 6.87 10.16 13.35 16.44

lb/ft 7.16 10.56 13.85 17.03 8.08 11.95 15.70 19.34

Sq In 9.50 11.34 14.92 18.41 11.46 13.70 18.06 22.33

lb/ft 11.17 13.33 17.55 21.65 13.47 16.11 21.24 26.27

Ordering Instructions:
Step 1: Choose Outside Diameter Outside Diameter 8 9 10 12 Diameter Code 8OD 9OD 10OD 12OD Step 2: Choose Wall Thickness Wall Thickness 1/4 5/16 3/8 1/2 5/8 Step 5: Build Catalog Number Outside Diameter Thickness Code 250W 312W 375W 500W 625W Step 3: Choose Alloy Alloy Number 6061 6063 6101 Alloy Code X Y Z Step 4: Choose Temper Temper T6 T61 T63 Temper Code T6 T61 T63

Wall Thickness

Alloy Code

Temper

Example: To order 8 inch OD 1/2 wall 6101-T61 Alloy Bus Pipe 8OD

500W

T61

Completed Catalog Number is 8OD500WZT61.

SS-6 5

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

Physical and Electrical Properties of Large Diameter Round Tube

Current Rating 60 Hz Amp Indoor 3805 4555 5045 5190 4255 5100 5650 5980 5185 5635 6255 6640 6155 6685 7415 7850 Outdoor 4720 5645 6250 6435 5245 6285 6965 7370 6355 6910 7670 8140 7480 8125 9015 6545

A Outside diameter (In)

B Wall thickness (In) 0.250 0.375 0.500 0.625 0.250 0.375 0.500 0.625 0.312 0.375 0.500 0.625 0.312 0.375 0.500 0.625 Area Sq In Weight lb/ft

Inductive DC Moment Reactance Resistance of Inertia 1 ft spacing at 20oC 1 in4 60 Hz-Xa microhms/ft microhms/ft 45.70 65.44 83.20 99.20 65.80 94.70 121.00 145.00 111.50 131.50 168.80 203.10 195.80 231.60 299.20 362.30 25.80 26.00 26.20 26.50 23.20 23.30 23.40 23.60 20.60 20.70 20.90 21.00 16.30 16.40 16.60 16.70 2.348 1.591 1.213 0.987 2.079 1.406 1.070 0.869 1.505 1.260 0.958 0.776 1.247 1.043 0.791 0.640

Rac/Rda at 70oC

AC Resistance at 70oC 60 Hz microhms/ft 2.8070 1.9470 1.5730 1.4140 2.4860 1.7220 1.3890 1.2480 1.8140 1.5430 1.2430 1.1160 1.5040 1.2780 1.0280 0.9219

6.09 8.98 11.78 14.48 6.87 10.16 13.35 16.44 9.50 11.34 14.92 18.41 11.46 13.70 18.06 22.33

7.16 10.56 13.85 17.03 8.08 11.95 15.70 19.34 11.17 13.33 17.55 21.65 13.47 16.11 21.24 26.27

1.006 1.030 1.091 1.206 1.006 1.030 1.092 1.308 1.015 1.031 1.092 1.210 1.015 1.031 1.093 1.213

10

12

Notes

1. Current ratings listed in the Tables are based on 30oC temperature rise over 40oC ambient horizontally mounted conductors, with spacing sufcient to eliminate proximity effects, generally assumed not to be signicant if spacing is 18 in. or over. Conduction of heat by supporting structures and taps can appreciably affect the ratings. 2. Conductors with a 2ft/sec crosswind. Nominal oxidized surface (e=0.50) 3. Current Ratings for direct current are close to those of alternating current for all except the larger sizes; and for them, the increase for dc bus is about 1.5 percent.

SS-6 6

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

Rectangular Bar
Rectangular shapes are the all-purpose rigid conductor for switchgear, control apparatus and busways. The use of multiple bar bus can provide a large surface area for heat dissipation. Joints and taps are easily made by bolting or welding; it is also easy to make off-sets and 90-degree bends. For direct current, the capacity of a rectangular bar bus conductor can be controlled by varying the size or number of bars in parallel. The same is true of alternating current up to certain limits. Special arrangements of laminations are used for high-amperage alternating current.

Thickness A In

Width B In 0.375 0.500 0.500 0.625 0.750 0.875 1.000 1.000 1.250 2.000 2.500 4.000 0.375 0.500 0.625 0.750 0.750 0.875 1.000 2.000 0.500 0.750 1.000 1.250 1.500 2.000 2.500 3.000 3.250 4.000

f-1 In 0.031 0.016 0.031 0.062 0.031 0.062 0.031 0.062 0.062 0.031 0.031 0.031 0.031 0.031 0.031 0.016 0.031 0.094 0.062 0.094 0.031 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125

Estimated Weight per lb/ft 0.055 0.074 0.074 0.090 0.110 0.127 0.149 0.145 0.184 0.299 0.371 0.599 0.084 0.112 0.140 0.169 0.168 0.187 0.222 0.442 0.149 0.209 0.284 0.359 0.434 0.584 0.734 0.884 0.959 1.184

Thickness A In 0.250

Width B In 4.500 5.000 6.000 7.000 8.000

f-1 In 0.125 0.125 0.125 0.125 0.125 0.062 0.188 0.062 0.187 0.062 0.187 0.187 0.187 0.187 0.062 0.250 0.062 0.062 0.062 0.062 0.062 0.062 0.062 0.062 0.125 0.375 0.062 0.031 0.250 0.062 0.188

Estimated Weight per lb/ft 1.334 1.484 1.784 2.084 2.384 0.277 0.527 0.895 0.864 1.120 1.314 1.764 2.214 2.664 3.596 0.385 0.896 1.196 1.796 2.396 2.996 3.596 4.796 5.996 0.884 3.455 4.495 1.498 9.535 11.996 14.364

0.125

0.375

0.625 1.25 2 2 2.5 3 4 5 6 8

0.188

0.5

0.75 1.5 2 3 4 5 6 8 10

0.250

0.75

1 4 5

1.25 8 10 12

SS-6 7

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

Ordering Instructions:
Step 1: Width of Bar Width of Bar 3/8 1/2 5/8 3/4 7/8 1 1 1/4 1 1/2 2 2 1/2 3 3 1/4 4 4 1/2 5 6 7 8 10 12 Width Code R375 R500 R625 R750 R875 R1i R125i R15i R2i R25i R3i R325i R4i R45i R5i R6i R7i R8i R10i R12i R125i Width Code Step 5: Build Catalog Number Step 2: Thickness of Bar Thickness of Bar 1/8 3/16 1/4 3/8 1/2 3/4 1 Thickness Code 125W 188W 250W 375W 500W 750W 100W Step 3: Choose Alloy Alloy Number 6061 6063 6101 Alloy Code X Y Z Step 4: Choose Temper Temper T6 T61 T63 Temper Code T6 T61 T63

Thickness Code

Alloy Code

Example: To order 1 1/4wide x 1/8 wall thickness 6101-T6 Bus Bar

125W

T6

Completed Catalog Number is R125i125WZT6.

SS-6 8

a
Sizes (Inches) 1/4 x 1 1 1/2 2 3 4 5 6 7 3/8 x 2 3 4 5 6 8 10 1/2 x 3 4 5 6 8 10 Sizes (Inches) 1/4 x 1 1 1/2 2 3 4 5 6 8 3/8 x 2 3 4 5 6 8 1/2 x 3 4 5 6 8

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

Current Rating of Rectangular Aluminum Bus Bar Arrangements

Amperes for 6101-T61 Alloy 57% IACS Conductivity
1 Bar DC 308 430 549 780 1005 1225 1443 1870 691 974 1249 1519 1785 2308 2822 1145 1462 1774 2081 2685 3278 1 Bar DC 300 420 535 750 955 1160 1320 1620 670 935 1190 1420 1630 2000 1100 1390 1650 1890 2310 60 HZ AC 300 415 530 735 930 1120 1270 1520 660 905 1130 1340 1520 1820 1050 1300 1520 1710 2050 DC 585 800 1010 1380 1720 2000 2220 2640 1230 1680 2080 2420 2710 3240 1870 2290 2680 3050 3640 60 HZ AC 308 429 545 768 980 1184 1381 1760 678 941 1191 1429 1657 2098 2534 1074 1369 1634 1892 2393 2880 DC 607 833 1051 1472 1878 2275 2665 3427 1340 1857 2356 2842 3320 4253 5165 2205 2782 3345 3897 4975 6209 2 Bars 60 HZ AC 601 817 1021 1410 1760 2092 2413 3034 1278 1709 2099 2483 2847 3569 4289 1991 2416 2828 3230 4014 4779 60 HZ AC 580 785 980 1310 1600 1830 2010 2320 1170 1550 1860 2110 2330 2700 1650 1960 2240 2490 2900 DC 605 1235 1552 2162 2749 3321 3881 4974 1989 2739 3460 4162 4848 6188 7493 3265 4100 4912 5706 7255 8763 DC 775 1060 1340 1850 2300 2670 2970 3410 1620 2250 2800 3250 3680 4210 2560 3150 3630 4060 4790 3 Bars 60 HZ AC 887 1194 1480 2000 2462 2905 3338 4183 1831 2384 2893 3387 3857 4774 5632 2742 3264 3778 4284 5276 6256 60 HZ AC 765 1020 1280 1700 2050 2330 2540 2840 1490 1960 2340 2650 2940 3270 2080 2470 2780 3050 3490 DC 1203 1637 2053 2851 3619 4365 5095 6517 2638 3620 4563 5479 6375 8119 9817 4324 5417 6477 7514 9531 1149 DC 905 1240 1560 2180 2740 3160 3440 3900 1920 2730 3360 3850 4280 4820 3070 3800 4370 4800 5510 4 Bars 60 HZ AC 1168 1561 1915 2530 3081 3625 4146 5152 2332 2946 3574 4178 4765 5875 6941 3297 3940 4580 5210 6246 7579 4 Bars 60 HZ AC 880 1180 1460 1940 2330 2610 2800 3080 1700 2220 2630 2940 3200 3490 2340 2750 3090 3330 3720

2 Bars

3 Bars

Notes: 1. Ratings based on 30oC rise over 40oC ambient in still but conned air (e=0.35), corresponding to usual indoor temperature. Vertical bar ampacity based on work by House and Tuttle. Horizontal bar ampacity from industry sources. 2. Space between bars is assumed equal bar thickness. 3. For ac phase spacings less than 18 inches an allowance for proximity effect must be made. 4. Ratings are based on horizontal mounting, in air with no attachments. For dc ratings of other alloys, multiply by: For 6101T61, 0.982; 6101-T63, 0.992; 6101-T64, 1.02; 6101-T65, 0.996. For 60Hz, the use of these multipliers is conservative. SS-6 9

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

Integral Web (IWBC)

This shape is used for station bus, open or enclosed and for the highcurrent bus of outdoor substations for distribution voltages, as well as for 600-volt bus for industrial plants. ACA offers the integral web bus conductor in both ventilated and non-ventilated conditions. The use of this shape makes it unnecessary to use the spacer clamps or welded tie-bars normally needed across the channels between insulator supports. Although convection airow is less than that of a face-toface channel arrangement, transverse strength is greater. The shallow grooves extruded on the surface facilitate location of the centers of drilled or punched holes for attaching base plates and taps.

Size Height A In 4 4 4 6 6 6 6 6 6 7 8 8 8 9 10 Width B In 4 4 4 4 4 4 5 6 6 7 5 5 8 9 10

Wall Thickness T In 0.156 0.250 0.312 0.250 0.375 0.375 0.375 0.375 0.550 0.500 0.375 0.500 0.500 0.625 0.625

Area Square Inch 2.439 3.781 4.460 4.780 6.020 6.950 7.600 8.600 11.220 12.840 9.080 11.750 16.120 20.040 23.500

Weight lb/ft 2.87 4.45 5.25 5.62 7.10 8.17 8.94 10.15 13.19 15.10 10.68 13.82 18.96 23.57 27.64

SS-6 10

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

Physical and Electrical Properties of Integral-Web Channel Bus Conductors

6101-T6 Alloy 55.0% IACS Conductivity (minimum)
Size A In 4 4 4 6 6 6 6 6 6 7 8 8 8 9 10 B In 4 4 4 4 4 4 5 6 6 7 5 5 8 9 10 Wall Thickness T In 0.156 0.250 0.312 0.250 0.375 0.375 0.375 0.375 0.550 0.500 0.375 0.500 0.500 0.625 0.625 Area Sq. In Weight lb/ft Moment of Inertia, in4 lx-x 3.876 5.788 6.892 16.35 14.50 22.91 25.19 29.73 40.05 64.83 52.88 66.84 103.5 162.3 255.6 ly-y 6.213 9.213 10.94 12.74 14.00 17.45 29.78 45.98 60.86 95.67 37.59 46.67 152.3 240.1 362.4 DC Resistance Rdc-20oC microhms per ft 6.88 4.42 3.75 3.50 2.78 2.41 2.20 1.95 1.49 1.30 1.84 1.42 1.04 0.83 0.71 Current Rating DC 70oC e=0.35 Indoors 2260 2810 3050 3480 3900 4200 4500 5020 5730 6530 5350 6090 7740 9060 10260 Inductive Reactance Xa-60Hz 1 ft spacing microhms per ft 39.02 39.76 40.80 34.80 36.60 ---32.50 27.60 31.40 27.60 29.10 30.00 24.70 21.60 19.10 Rac/ RDC70oC 60HZ 1.020 1.035 1.050 1.050 1.080 1.090 1.110 1.110 1.220 1.210 1.120 1.280 1.260 1.370 1.420 AC 60 Hz Resistance Rac-70oC microhms per ft 7.017 4.579 3.940 3.670 3.000 2.630 2.440 2.160 1.820 1.570 2.064 1.820 1.310 1.140 1.010 Current Rating AC-60Hz Indoor e=0.35 2240 2276 2980 3400 3760 4020 4320 4760 5190 5940 5060 5380 6890 7740 8610 Outdoor e= 0.50 2520 3115 3360 3780 4180 4470 4800 5270 5740 6540 5560 5910 7550 8450 9350

2.439 3.781 4.460 4.780 6.020 6.950 7.600 8.600 11.22 12.84 9.080 11.75 16.12 20.04 23.50

2.87 4.45 5.25 5.62 7.10 8.17 8.94 10.15 13.19 15.10 10.68 13.82 18.96 23.57 27.64

Note: 1. Current ratings are based on 6101-T61 alloy with standard vent-holes in web. For 6101-T6 reduce the rating by 2 percent. Indoor ratings are based on 30oC rise over 40oC ambient in still but unconned air, normally oxidized surface (e=0.35) and similarly for outdoor ratings, except 2 ft/sec cross wind (e=0.50). Horizontal mounting is assumed with spacing sufcient to eliminate proximity effects, generally assumed to be 18-in. or over. For temperature rise of 50oC above 40oC ambient, the indoor ratings for 30oC may be increased about 30 percent. Indoor ratings (D-C and A-C) calculated by computer and veried by test rounded. Outdoor ratings are calculations only. 2. For vent and notch arrangements, consult your ACA Sales Representative. The interior perimeter varies according to the washer diameters that are to be accommodated, and as to their location per NEMA spacing. The 12 in. x 12 in. size is a opposite of two symmetric extrusions bolted together.

Ordering Instructions:
Step 1: Choose Size of IWBC Size of IWBC 4 x 4 6 x 4 6 x 5 6 x 6 7 x 7 8 x 5 8 x 8 9 x 9 10 x 10 Size Code I44 I64 I65 I66 I77 I85 I88 I99 I101 Step 6: Build Catalog Number Size Code Step 2: Choose Wall Thickness Wall Thickness 5/32 1/4 5/16 3/8 0.550 1/2 Thickness Code 156W 250W 312W 375W 550W 500W Step 3: Choose Alloy Alloy Number 6061 6063 6101 Alloy Code X Y Z Step 4: Choose Temper Temper T6 T61 T63 Temper Code T6 T61 T63

Step 5: Choose Piece Length Piece Length is a whole number between 10 feet and 40 feet.

Thickness Code

Alloy Code

Temper

Vented

Example: To order 8 x 8 IWBC with 1/2 wall thickness 6101 T-6 Alloy I88

500W

T6

Completed Catalog Number is I88500WZT6V. To order 4 x 4 IWBC with 1/4 wall thickness 6063 T-6 Alloy Non-vented I44

250W

T6

Completed Catalog Number is I44250WYT6 SS-6 11

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

Channel
This Channel, which is really a pair of channels forming a hollow, ventilated square, is a practical choice for high-amperage direct or alternating current above 2,000 amperes per circuit. The aluminum channels may be placed back-to-back forming a conductor for applications such as d-c circuits, where skin effect is not a factor. For enclosed station bus where the space occupied by the conductor is critical, channel shapes of uniform thickness may be used. When the channels are assembled in pairs to form open tubes, they offer several advantages: high alternating-current ratings, high structural strength, at outside surfaces and virtually unrestricted interior cooling.

Dimensions (In) A Height 3 4 4 5 6 7 7 7 8 8 8 9 11 11 11 12 12 12 B Length of Leg 1.312 1.750 1.750 2.187 2.687 3.187 3.187 3.187 3.687 3.687 3.687 4.125 5.312 5.312 5.312 5.812 5.812 5.812 T Wall Thickness 0.250 0.250 0.625 0.625 0.437 0.375 0.562 0.625 0.375 0.500 0.625 0.625 0.250 0.312 0.562 0.250 0.312 0.625

Weight lb/ft

1.44 1.99 4.32 5.70 5.24 5.45 7.87 8.63 6.33 8.26 10.11 11.48 6.15 7.62 13.32 6.74 8.30 16.17

Outside Corner Radius Web Thickness Inches 0.250 0.375 0.500 0.625 Corner Radius Inches 3/8 1/2 5/8 3/4

SS-6 12

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

Physical and Electrical Properties of Aluminum Channel Bus Conductors

Single Channel Dimensions In. Moment of Inertia in4 lx-x 1.23 1.70 3.67 4.84 4.46 4.63 6.69 7.34 5.38 7.03 8.59 9.77 5.23 6.48 11.35 5.73 7.10 13.75 1.44 1.99 4.32 5.70 5.24 5.45 7.87 8.64 6.33 8.26 10.11 11.48 6.15 7.62 13.32 6.74 8.30 16.17 1.49 3.79 6.72 13.5 21.3 33.7 44.4 47.7 49.9 63.4 74.9 109.2 91.8 119.8 198.2 128.5 186.0 288.5 ly-y 0.18 0.46 0.74 1.60 2.83 4.33 6.15 6.72 6.91 8.64 11.1 14.9 14.4 17.7 29.8 19.0 27.5 45.3 Distance to Netural X In 0.397 0.500 0.627 0.750 0.794 0.893 0.935 0.989 1.020 1.070 1.100 1.210 1.400 1.420 1.510 1.530 1.570 1.670 Xa-60 Hz DC inductive Resistance Reactance at 20oC 1-ft spacing microhms/ft microhms/ft 46.2 39.2 40.2 33.8 29.7 24.8 25.2 25.4 22.0 22.1 22.4 19.1 14.3 14.4 14.7 12.1 12.4 12.7 5.820 4.210 1.946 1.475 1.602 1.542 1.068 0.973 1.327 1.017 0.832 0.732 1.367 1.103 0.631 1.248 1.013 0.520 Face to Face Pair Rac/Rdc at 70oC 60 Hz 1.04 1.04 1.32 1.36 1.13 1.16 1.35 1.44 1.21 1.29 1.37 1.47 1.11 1.18 1.44 1.15 1.35 1.53 AC Resistance at 70oC 60 Hz microhms/ft 7.19 5.21 3.05 2.38 2.15 2.13 1.71 1.67 1.41 1.56 1.35 1.28 1.80 1.55 1.08 1.70 1.62 0.945 AC Current Ratings 60 Hz Amp Indoor e=0.35 2300 2910 3660 4760 5800 6140 6790 6820 6240 6560 7900 8610 8100 8940 10400 8980 10050 11550 Outdoor e=0.55 2760 3500 4400 5700 6950 7350 8150 8450 7500 7900 9400 10500 9750 10800 12400 10800 12100 13700

Area Sq In W 3.933 4.188 4.375 5.000 6.000 7.000 7.000 7.000 8.000 8.000 8.000 9.000 11.00 11.00 11.00 12.00 12.00 12.00

Weight lb/ft

A 3 4 4 5 6 7 7 7 8 8 8 9 11 11 11 12 12 12

B 1.312 1.750 1.750 2.187 2.687 3.187 3.187 3.187 3.687 3.687 3.687 4.125 5.312 5.312 5.312 5.812 5.812 5.812

T 0.250 0.250 0.625 0.625 0.437 0.375 0.562 0.625 0.375 0.500 0.625 0.625 0.250 0.312 0.562 0.250 0.312 0.625

Notes: 1. Physical properties are for single channels; electrical properties are for two channels in face-to-face arrangement. 6101-T61 alloy, 57.0% IACS Conductivity (minimum) 2. Ratings are based on 30oC rise over 40oC ambient temperature in still but unconned air for usual indoor conditions (e=0.35), and for 2 ft/sec cross wind for usual outdoor conditions (e=0.50). 3. For temperature rise of 50oC above 40oC ambient, an increase of about 30 percent of current rating indoors is generally accordance with tests.

Ordering Instructions:
Step 1: Choose Height of Channel Height of Channel 3 4 5 6 7 8 9 11 12 Height Code C3 C4 C5 C6 C7 C8 C9 C11 C12 Height Code Step 2:Choose Wall Thickness Wall Thickness 1/4 5/16 3/8 7/16 1/2 9/16 5/8 Thickness Code 250W 312W 375W 437W 500W 562W 625W Step 3: Choose Alloy Alloy Number 6061 6063 6101 Alloy Code X Y Z Step 4: Choose Temper Temper T6 T61 T63 Temper Code T6 T61 T63

Step 5: Build Catalog Number

Thickness Code

Alloy Code

Temper

Example: To order 4 inch 1/4 wall 6101-T6 Alloy 30 ft lengths Channel Bus C4

250W

T6

Completed Catalog Number is C4250WZT6.

SS-6 13

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

Bus Square Tube

This type of bus has low skin-effect ratio much like that of round tubes, with the additional advantage of requiring simpler adapter plates for mounting on pedestal insulators. It is often used for generator phase and station bus in protected enclosures. The most commonly used alloys are 6101-T6 and 6063-T6, with staggered ventilation holes on top and bottom surfaces. The ampacity values for standard sizes are shown for dc and ac current, using 30C rise over 40C ambient in still air.

Dimensions A 3 3 3 4 4 4 5 5 5 6 6 6 B 3/8 1/2 3/4 1/2 1/2 3/4 3/4 3/4 3/4 3/4 3/4 3/4 C 1/4 3/8 1/2 1/4 3/8 1/2 1/4 3/8 1/2 1/4 3/8 1/2

Area Sq In 2.643 3.736 4.571 3.589 5.236 6.571 4.482 6.575 8.571 5.482 8.075 10.57

Weight lb/ft 3.108 4.394 5.375 4.221 6.158 7.727 5.271 7.733 10.08 6.447 9.497 12.43

Ordering Instructions:
Step 1: Choose Size Size of Tube 3 4 5 6 Size Code SQ3 SQ4 SQ5 SQ6 Step 2 :Choose Wall Thickness Wall Thickness 1/4 3/8 1/2 Thickness Code 250W 375W 500W Step 3: Choose Alloy Alloy Number 6061 6063 6101 Alloy Code X Y Z Step 4: Choose Temper Temper T6 T61 T63 Temper Code T6 T61 T63

Step 5: Build Catalog Number Size Code

Thickness Code

Alloy Code

Temper

Example: To order 4 inch 1/2 wall 6101-T6 Alloy Square Tube Bus SQ4

500W

T6

Completed Catalog Number is SQ4500WZT6.

SS-6 14

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

Physical and Electrical Properties of Square Aluminum Tubular Conductors

57% IACS Conductivity (minimum)
For 6101-T61 Square size A (in) 3 3 3 4 4 4 5 5 5 6 6 6 Outside Corner Radius B (in) 3/8 1/2 3/4 1/2 1/2 3/4 3/4 3/4 3/4 3/4 3/4 3/4 Web Thickness C (in) 1/4 3/8 1/2 1/4 3/8 1/2 1/4 3/8 1/2 1/4 3/8 1/2 2.643 3.736 4.571 3.589 5.236 6.571 4.482 6.575 8.571 5.482 8.075 10.57 3.108 4.394 5.375 4.221 6.158 7.727 5.271 7.733 10.08 6.447 9.497 12.43 3.272 4.215 4.598 8.215 11.30 13.06 16.26 22.76 28.32 29.36 41.59 52.35 Area Sq in Weight lb/ft Moment of Inertia l in4 Xa 60 Hz Inductive Reactance 1-ft Spacing microhms/ft 45.5 46.1 46.9 38.7 39.0 39.6 33.5 33.8 34.1 29.1 29.4 29.6 DC resistance at 20oC microhms/ft 5.408 3.825 3.126 3.982 2.729 2.175 3.189 2.173 1.667 2.607 1.770 1.352 Rac/Rdc at 70oC 60 Hz 1.04 1.09 1.18 1.05 1.11 1.21 1.06 1.13 1.24 1.08 1.15 1.28 AC Resistance at 70oC 60Hz microhms/ft 6.683 4.954 4.384 4.968 3.600 3.127 4.106 2.918 2.457 3.346 2.418 2.056 AC Current Rating 60 Hz Amp e=0.35 1880 2170 2250 2450 2880 3040 2980 3490 3810 3540 4170 4570 e=0.50 2300 2640 2760 3020 3550 3760 3700 4340 4730 4420 5200 5640

Notes: 1. Current ratings are based on 30oC rise over 40oC ambient, conductors horizontally mounted and spaced sufciently to eliminate proximity effects. For temperature rise of 50oC above 40oC ambient, increase ratings by about 30 percent. The e=0.35 rating applies to tubes in still but conned air (usual indoor condition) with normal oxidized surface. The e+0.90 rating applies similarly but with at nonmetallic paint. 2. Tabulated values apply to unventilated tubes. Ventilated tubes have about 8 percent less weight. Add 15 percent to current ratings of ventilated tubes having staggered ventilating holes spaced 4-in. apart longitudinally with hole diameters as follows: For 3-in. tube, 1 1/4 in.; for 4-in.tube, 1 1/2 in.; for 5-in. tube. 1 5/8 in.; for 6-in. tube, 1 3/4 in.

SS-6 15

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

Universal Angle Bus Conductor (UABC)

The universal angle bus conductor is used for moderate-size outdoor substations at distribution voltages. Centerline grooves make it easy to locate bolt holes. The bus can be mounted directly on insulator caps, since both legs are of uniform thickness. In contrast to the large number of ttings sometimes required for bus installation, angle can be easily installed using bolts. Terminal connectors are used to make taps or exible connections. Angle shapes are usually made of 6101-T6 alloy.

Size W In 3 1/4 4 4 4 1/2 5 T In 1/4 1/4 3/8 3/8 3/8 A 1.500 1.875 1.875 2.187 2.313

Notching Dimensions B 1.750 1.750 1.750 1.750 1.750 C D 2.375 2.813 2.813 3.006 3.256

Area (Sq In) 1.57 1.93 2.85 3.23 3.60

Weight lb/ft lb/ft 1.83 2.27 3.36 3.80 4.24

--2.00 2.00 2.00 2.00

Ordering Instructions:
Step 1: Choose Size Size of UABC 3 1/4 4 4 1/2 5 Size Code A325 A400 A450 A500 Step 2: Choose Wall Thickness Wall Thickness 1/4 3/8 Thickness Code 250W 375W Step 3: Choose Alloy Alloy Number 6061 6063 6101 Alloy Code X Y Z Step 4: Choose Temper Temper T6 T61 T63 Temper Code T6 T61 T63

Step 5: Build Catalog Number Size Code

Thickness Code

Alloy Code

Temper

Example: To order 5 3/8 Wall Thickness 6106-T6 Alloy UABC A500

375W

T6

Completed Catalog Number is A500375WZT6.

SS-6 16

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

Physical and Electrical Properties of Uniform-Thickness Angle Bus Conductors

6101-T6 alloy 55.0% IACS Conductivity (minimum) (4)
Moment of Inertia in4 lx or y 1.60 3.02 4.35 6.31 8.75 lz 0.65 1.18 1.75 2.61 3.50 Minimum Distance to Neutral Axis x or y 0.91 1.09 1.14 1.26 1.39 z 1.30 1.51 1.60 1.77 1.96 Xa - 60 Hz Inductive Reactance 1-ft Spacing microhms/ft 51.41 46.60 46.62 43.93 41.52 AC Current Rating 60 Hz Amp (1) Indoor e=0.35 1300 1550 1850 2050 2250 Outdoor e=0.50 1902 2236 2654 2885 3130

Size (3) W (in) 3 1/4 4 4 4 1/2 5 T (in) 1/4 1/4 3/8 3/8 3/8 Area Sq in 1.57 1.93 2.85 3.23 3.60 Weight lb/ft 1.83 2.27 3.36 3.80 4.24

DC Resistancy at 20oC microhms/ft 11.20 9.07 6.14 5.42 4.86

Rac/Rdc at 70oC 60 Hz 1.024 1.045 1.115 1.145 1.175

AC Resistancy at o 70 C 60Hz microhms/ft 11.49 9.46 6.85 6.20 5.71

Notes: 1. Indoor current ratings are based on 30oC rise over 40oC ambient in still but unconned air, normally oxidized surface (e=0.35). Outdoor ratings are based similarly, but with 2 ft/sec crosswind (e=0.50). Horizontal mounting is assumed with spacing sufcient to eliminate proximity effects, generally assumed to be 18-in. or over. Indoor ratings based on work by House and Tuttle. Outdoor ratings from IEEE paper by Prager, Pemberton, Craig and Bleshman. 2. Back-to-back angles are to be considered as separate members; not as a composite. 3. Alignment grooves are extruded to facilitate centering of holes according to NEMA standard spacings. 4. A modication of this design has a lug at top that does not interfere with bolting, wet it strengthens the shape against tendency to roll-over to the z-z axis in long spans subjected to large lateral short circuit forces. For equal weight of shape, the z-z radius of gyration is increased by 20 percent. The stress that causes roll-over is thereby increased about 40 percent.

SS-6 17

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

Mechanical Properties of Aluminum Bus Conductors

The Table below shows the mechanical properties of the aluminum alloys and tempers generally used for bus conductor. From this information, the best combination of properties can be selected for a particular application. For example, where the cost of power is important, high electrical conductivity is a key factor. In outdoor applications, mechanical properties are a prime consideration. Other factors, such as yield strength and tensile strength may are taken into consideration.

Mechanical Properties of Aluminum Bus Conductor and Related Alloys

Alloy and Temper Tensile Strength (ksi) at 20oC (68oF) Minimum Ultimate 8.5 6101-T6 6101-T61 6101-T63 9101-T64 6101-T65 Extruded Pipe (c) 6061-T6 6063-T6 0.125-0.500 0.125-0.749 Extruded rod, bar tube, pipe 0.750-1.499 1.500-2.000 0.125-0.500 0.125-1.000 0.125-0.749 Pipe size 1.0 and over Pipe size, all 29.0 20.0 18.0 15.0 27.0 15.0 25.0 38.0 30.0 Minimum Yield 3.5 25.0 15.0 11.0 8.0 22.0 8.0 20.0 35.0 25.0 45.0 35.0 40.0 31.0 10.0 min 8.0 min 32.0 28.0 Typical (a) Elongation (Percent - in 2 in. or 4 Dia.) 35.0 15.0

Product

Thickness in Inches

Typical Ultimate

Typical Yield

(a) Elongation values apply to specimens of sizes related to product uses. (b) Values apply to ANSI net stress area of regular or semi-nished bolts. (c) Vaules apply to ASRM B241 seamless pipe.

SS-6 18

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

Bending & Forming Bus Conductor

Flatwise Bends for Rectangular Bus

Aluminum bus conductors can be formed by the same procedures and practices that are used for other metals. The most important factors governing to consider when bending bus conductor are: 1. The ductility of the conductor 2. The size and shape of the conductor 3. The method of bending 4. The bending equipment used A metal must be ductile enough to allow stretching and compression to take place. Elongation alone is not a complete criterion for ductility. The ration of yield strength to tensile strength must also be taken into account. A combination of a high elongation value and a low ratio of yield strength to tensile strength provides the most satisfactory ductility. The size and the shape of the bus conductor is another factor that must be taken into consideration. For example, in case of a tube, the sharpness of a bend depends not only on the diameter of the tube, but also on the ratio of wall thickness to the diameter. When making edgewise bends of rectangular bar, tests have shown that the radius (in terms of width of the bar) around which a bar can be bent satisfactorily depends not only on the ductility of the car but also on its ratio of width to thickness. Extruded, rolled, and sawed-plated bus bars can be bent atwise at room temperature through an angle of 90 degrees to minimum inside radii. Tubular conductors made alloys 6063-T6 and 6061-T6 are often bent to form turns and offsets In these cases, specications should require seamless pipe made by hollow ingot process (ASTM B241). Ideally, the ratio of tensile yield to tensile ultimate should not exceed 0.85. It is vital to specify that severe forming will be encountered and optimum heat treatments are required. For substations, inside radii of ve to seven times the nominal pipe size for ASA schedules 40 and 80 pipe of 6063-T6 and 6061-T6 alloys should produce satisfactory results with conventional bending tools.

Type of Bar

Alloy and Temper 6101-T6

Thickness in 0.125-0.375 0.376-0.500 0.125-0.500

Radius min.1 2 x thickness 2 1/2 x thickness 1 x thickness 2 x thickness 3 x thickness 4 x thickness 1 x thickness 1 1/2 x thickness 2 1/2 x thickness 1 x thickness 2 1/2 x thickness 1 x thickness 2 x thickness

6101-T61

0.501-0.749 0.750-1.000 1.001-1.625

Extruded 6101-T63

0.125-0.375 0.376-0.500 0.501-1.000 6101-T64 0.125-0.750 0.751-1.00 0.125-0.500 0.501-0.749

6101-T65

1. Applicable to widths up through 6 inches in the T6, T61, T63 and T65 tempers and to widths up through 12 inches for all other listed tempers. Blend radii for greater widths are subject to inquiry.

SS-6 19

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

Deection Values of Schedule 40 Aluminum Pipe

Conditions Nominal Pipe Size In 1 1 1/4 1 1/2 2 Bare 2 1/2 3 3 1/2 4 5 6 1 1 1/4 1 1/2 2 1/2 in. ice 2 1/2 3 3 1/2 4 5 6 1 1 1/4 1 1/2 1/2 in. ice 4 lb Wind Plus Constant 2 2 1/2 3 3 1/2 4 5 6 1 1 1/4 1 1/2 2 1 in. ice 2 1/2 3 3 1/2 4 5 6 10 0.15 0.09 0.07 0.04 0.03 0.02 0.02 0.01 0.01 0.01 0.43 0.24 0.17 0.10 0.06 0.04 0.03 0.02 0.01 0.01 0.56 0.30 0.21 0.12 0.07 0.04 0.03 0.02 0.01 0.01 0.88 0.47 0.34 0.18 0.10 0.06 0.04 0.03 0.02 0.01 15 0.76 0.46 0.35 0.21 0.15 0.10 0.08 0.06 0.04 0.03 2.20 1.23 0.88 0.52 0.30 0.19 0.14 0.11 0.07 0.04 2.85 1.53 1.08 0.61 0.34 0.21 0.15 0.12 0.07 0.05 4.44 2.37 1.69 0.92 0.50 0.31 0.22 0.16 0.10 0.06 20 2.39 1.45 1.09 0.68 0.47 0.31 0.24 0.19 0.12 0.08 6.96 3.89 2.80 1.63 0.96 0.60 0.44 0.34 0.21 0.14 9.02 4.84 3.40 1.93 1.09 0.67 0.49 0.37 0.22 0.15 14.03 7.47 5.35 2.91 1.59 0.97 0.70 0.52 0.31 0.21 18.49 13.07 7.09 3.87 2.37 1.70 1.27 0.76 0.50 14.95 8.03 4.91 3.53 2.63 1.57 1.04 15.06 9.20 6.53 4.88 2.91 1.92 15.69 11.14 8.32 4.97 3.28 18.06 13.49 8.05 5.26 20.56 11.74 8.02 11.81 8.30 4.70 2.65 1.64 1.19 0.90 0.55 0.36 9.75 5.49 3.40 2.47 1.86 1.13 0.75 10.17 6.30 4.58 3.45 2.10 1.39 10.76 7.81 5.89 3.57 2.37 12.51 9.43 5.72 3.80 14.38 8.72 5.79 9.62 6.83 4.00 2.30 1.47 1.08 0.83 0.51 0.34 8.36 4.89 3.06 2.24 1.71 1.05 0.71 9.05 5.72 4.16 3.17 1.95 1.32 9.75 7.16 5.42 3.34 2.25 11.46 8.73 5.37 3.60 13.31 8.19 5.49 3.55 2.67 1.65 1.15 0.76 0.58 0.45 0.29 0.20 3.46 2.38 1.58 1.20 0.94 0.61 0.42 4.22 2.93 2.21 1.74 1.12 0.79 5.00 3.78 2.96 1.91 1.34 6.07 4.76 3.08 2.15 7.26 4.69 3.28 25 30 35 40 45 50

Note: These are maximum deection values in inches for a simple beam with uniformly distributed load. For beams xed at both ends, the deection will be one-fth of the values given. Deection d1 for any other span L1 may be obtained from the relation: d1=d L14/L4 SS-6 20

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

Deection Values of Schedule 80 Aluminum Pipe

Nominal Pipe Size In 1 1 1/4 1 1/2 2 Bare 2 1/2 3 3 1/2 4 5 6 1 1 1/4 1 1/2 2 1/2 in. ice 2 1/2 3 3 1/2 4 5 6 1 1 1/4 1 1/2 1/2 in. ice 4 lb Wind Plus Constant 2 2 1/2 3 3 1/2 4 5 6 1 1 1/4 1 1/2 2 1 in. ice 2 1/2 3 3 1/2 4 5 6

Conditions

10 0.16 0.10 0.07 0.04 0.03 0.02 0.01 0.01 0.01 0.01 0.40 0.22 0.16 0.09 0.05 0.03 0.02 0.02 0.01 0.01 0.50 0.27 0.94 0.10 0.06 0.04 0.03 0.02 0.01 0.01 0.76 0.40 0.28 0.15 0.09 0.05 0.04 0.03 0.02 0.01

15 0.81 0.49 0.36 0.23 0.16 0.10 0.08 0.06 0.04 0.03 2.01 1.11 0.79 0.46 0.28 0.17 0.13 0.10 0.06 0.04 2.53 1.34 2.97 0.53 0.31 0.19 0.14 0.10 0.06 0.04 3.86 2.02 1.40 0.77 0.44 0.26 0.19 0.14 0.08 0.05

20 2.56 1.54 1.15 0.72 0.49 0.33 0.25 0.19 0.12 0.09 6.34 3.51 2.51 1.45 0.88 0.55 0.40 0.31 0.20 0.13 7.99 4.24 7.24 1.66 0.98 0.60 0.44 0.33 0.20 0.13 12.21 6.39 4.42 2.43 1.38 0.84 0.60 0.45 0.26 0.17

25

30

35

40

45

50

3.77 2.82 1.76 1.21 0.80 0.60 0.47 0.31 0.21 3.65 2.50 1.66 1.25 0.98 0.63 0.44 6.76 4.64 3.08 2.32 1.82 1.17 0.82 7.92 5.25 3.97 3.11 2.01 1.40 8.40 6.36 4.98 3.21 2.25 9.69 7.58 4.89 3.43

8.65 6.12 3.54 2.15 1.35 0.99 0.75 0.49 0.32 7.40 4.46 2.80 2.05 1.56 1.01 0.67 13.72 8.33 5.23 3.80 2.89 1.88 1.24 14.20 8.93 6.50 4.95 3.20 2.11 14.30 10.47 7.96 5.13 3.38 15.96 12.14 7.81 5.15

10.36

4.06 2.39 1.47 1.07 0.81 0.49 0.32

8.42 4.95 3.06 2.21 1.67 1.01 0.67

15.60 9.17 5.66 4.10 3.09 1.88 1.24 7.00 5.28 3.20 2.11 11.21 8.45 5.13 3.38 17.08 12.88 7.81 5.15 15.65

15.80 10.79 5.94 3.37 2.04 1.46 1.09 0.65 0.42 12.46 6.99 4.24 3.03 2.26 1.34 0.87 23.09 13.10 7.93 5.61 4.19 2.48 1.61 22.34 13.53 9.60 7.16 4.25 2.75 21.67 15.52 11.54 6.85 4.41 23.65 17.59 10.44 6.72

Note: These are maximum deection values in inches for a simple beam with uniformly distributed load. For beams xed at both ends, the deection will be one-fth of the values given. Deection d1 for any other span L1 may be obtained from the relation: d1=d L14/L4 SS-6 21

Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

Welding Aluminum Bus to Aluminum Connectors

Welding of aluminum in electrical construction offers a superior and economical means of joining conductors. Electric arc welding using an inert gas shield produces mechanically and electrically sound joints requiring no ux or special surface preparation other than the cleaning of the surface to be welded. A welded connection that is mechanically satisfactory is also electrically satisfactory. With welded connections, there is an essentially homogeneous union that gives a permanent stable connection. It is not necessary to try to produce a connection with the same resistance as bus itself in order to have a stable permanent joint. There are bus connectors where it is important to insure a resistance ratio of unity with the conductor itself. Small differences in resistance can affect the current distribution in some bus systems. Some bus systems require equalization bars. Welded connections are an ideal solution to both problems. Such connections can be made by following procedures outlined in The American Welding Society Handbook Welding Aluminum.

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Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

General Welding Specications for Tubular Aluminum Bus Conductor

The following items cover key points that should be included in specications for welding aluminum bus conductors. It is recommended that the references be reviewed in the preparation of proprietary welding specications. 1. The welding process and all welding operators should be qualied in accordance with the Aluminum Association, Aluminum Construction Manual Section 7.2.4 Qualication of Welding Procedure and Welding. 2. All Joints to be welded should be free of moisture and hydrocarbon. Moisture can be removed thermally, but the temperature applied should not exceed 250oF (121oC). Degreasing should be done with a non-toxic solvent so as to leave a minimum of residual on the parts. Sufcient time must be allowed for evaporation of the solvent prior to welding. Wire brushing with a stainless steel wire brush should be employed after solvent cleaning to remove thick heat-treat oxide lms, water stains, etc., to permit optimum fusion and soundness of the weld. 3. All welds should be made by the gas metal-arc (MIG) or the gas tungsten-arc (TIG) welding process. Reversed polarity direct current should be used for MIG welding, whereas alternating current should be used for TIG welding. The shielding gas should be welding grade Argon, Helium, or a mixture of the two. Filler alloy 4043 should be used. 4. The working area should be substantially draft free and should be protected from atmospheric contamination. 5. All connections should be checked before, during and after the weld is made. Before the weld is begun, visually inspect the connection to determine proper edge preparation and alignment. During the weld, maintain a smooth and continuous ow of metal into the joint and maintain a constant current setting on the welding station. When several passes are to be made, check the previous pass before laying down the next one to enable detection of poor fusion or cracks. Defective areas should be removed with a dry chisel prior to application of subsequent weld passes. After the weld has been complete, it should be visually inspected again for quality and to insure the weld bead is of the correct size. The cross sectional area of the weld should not be less than that of the smallest member being joined. 6. Members being joined should be tack welded in place to prevent misalignment during the welding process.

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Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor
ACASS0602

Frequently Asked Questions

Do I use seamless pipe or structural pipe for substation construction? For substation construction, seamless pipe should be used. Extruded structural pipe is produced with a bridge-type die. In the bridge die method of extrusion, the solid ingot is broken up and then rejoined in the weld chamber of the die. Thus, the pipe contains two or more die welds along its length. This pipe is intended for use in structural applications such as highway and bridge rails, chain link fence posts, sign structures, lighting brackets, etc. Structural pipe is not intended for applications involving uid pressure or repeated exure as there is a possibility of splitting along the die welds. Tubular bus in substations is frequently subjected to aeolian vibration which produces repeated exure. Seamless pipe is extruded from hollow extrusion ingot by the die and mandrel method. The cross section is continuous; there are no die welds to separate under repeated exure. For more information about structural pipe look at ASTM standard B-249-00 and for seamless pipe look at ASTM standard B-241-00. What is the difference between bus pipe and bus tube? Bus Pipe is manufactured to a nominal (not actual) diameter. The wall thickness is described by a schedule. i.e. 4 Sch40. Bus Tube is a round hollow material manufactured to a specic outside diameter (O.D.) and wall thickness. It is produced to meet the end users requirements. Does alloy and temper matter? Yes, the alloy and temper specify the conductivity and mechanical properties. What is the maximum length of bus conductor I can buy? Most bus conductor is sold in lengths of 10 to 40 feet. Longer lengths are available in various sizes. Contact the ACA Commercial Team for any lengths over 40 feet. Can I order custom sizes or custom extrusions? Yes, contact the ACA Commercial Team for custom sizes of bus conductor and custom extrusions.

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Alcoa Conductor Accessories

A division of AFL Telecommunications

Bus Conductor Catalog

ACASS0602

General Terms and Policies

ORDER ACCEPTANCE: Orders are subject to acceptance by Alcoa Conductor Accessories (ACA), a division of Alcoa Fujikura, Ltd. (AFL) at its ofces in Spartanburg, South Carolina, and will be accepted only upon the terms and conditions shown on the face and reverse side of ACAs acknowledgment of order. TERMS: Net 30 days from the date of AFLs invoice. No cash discount is allowed, without written agreement prior to acceptance of order. A service charge may be may applied to all invoices not paid according to accepted terms. MINIMUM ORDER CHARGE: All orders, accepted by ACA, for manufacture are subject to a minimum order charge of $200.00 plus applicable transportation and/or handling charges. Any additions to orders already placed by the Customer may be considered as new orders. This minimum order charge may also apply to credit card purchases. Certain manufactured products have minimum order quantities that may be applied. QUOTATIONS AND PRICES: All prices, quotations, and specications provided verbally and/or contained on the face of ACAs or AFLs quotation form are valid for a maximum of 30 days, and are subject to change without notice. All quotations made for ACA product are made subject to prior sale. CANCELLATION: Cancellation notication of a previously accepted order, in part or in full, must be received by ACA, in writing, at its ofces in Spartanburg, SC. Cancellation of standard and/or normally stocked items will be allowed only when Customer agrees to pay cancellation charges based on the accumulated value of in-process items or other commitments made by ACA to supply the material in accordance with the Customers original purchase order. The minimum cancellation charge will be equal to $50.00, or the actual accumulated value of in-process and unshipped material,

whichever is greater. Special ordered or nonstandard items are non-cancelable. DELIVERY AND TRANSPORTATION: Transmission, Distribution & Alumoweld products - Unless otherwise stated herein, all ACA products are sold F.O.B. shipping point. ACA will deliver, and bear the cost of transportation of such products to such destination in accordance with the provisions of this paragraph, for orders totaling $2000.00 or more purchased for manufacture and shipment at one time, to one destination (excluding Alaska, Hawaii, Puerto Rico, and all International destinations). Shipments to Alaska, Hawaii, Puerto Rico, and all International destinations totaling $2000.00 or more will be made F.O.B. shipping point, freight allowed to the continental United States point of exit. Transportation costs on orders totaling less than $2000.00 purchased for manufacture and shipment will be the responsibility of the purchaser and will be prepaid and added to the account of the purchaser unless specied otherwise, in writing, prior to order acceptance. The method and agency of transportation, and the routing will be designated by ACA. Excess packing, shipping, and transportation charges resulting from compliance with Customers request with respect to the use of any agency or method of transportation or routing by ACA will be billed to the Customers account. In the case of Customer pickup, the Customers truck is designated as the shipping point and ACA will not deliver, or bear any cost of shipment or transportation, or make allowances with respect thereto, beyond loading on Customers truck (whether owned by, leased to, or otherwise under contract to the Customer). Bus Conductor - All bus conductor shipped direct from the extrusion mill will be shipped freight allowed. All bus conductor shipped from stock will be shipped prepaid and added to customer account. Shipping terms and packaging must be determined at time of order entry and should be clearly indicated on original customer purchase order. QUANTITY TOLERANCE: Unless otherwise stated within a current ACA price schedule or authorized, in writing by an ACA agent, the following standard quantity tolerances are applicable: Alumoweld wire: - 0 + 10% length tolerance

STANDARD PACKAGES: A broken package charge may apply to quantities ordered that deviate from standard package quantities as shown in the ACA catalog and/or price schedules. MINIMUM ORDER QUANTITIES: Certain standard and non-standard items are subject to minimum order quantities, as published in ACAs catalogs, price schedules, or quotations. SPECIAL ITEMS CHARGES: Any item that is deemed special or non standard, may be subject to any or all of the following fees: set up charges, tooling charges, minimum quantity charges and miscellaneous fabrication charges. RETURN GOODS POLICY: No material will be accepted for return without a written Returned Material Authorization (RMA) from ACAs ofces in Spartanburg, SC. A copy of this RMA must be included with the material being returned, or the shipment is subject to refusal by the ACA receiving department. Return Material Authorizations will remain valid for 90 days from the date of issue. Request for return of material must be made, in writing, within 12 months of the original shipping date and must reference the original ACA invoice number. The material to be returned must be of current design, non-obsolete and in good reusable condition. Non-standard items manufactured to the Customers specication will not be accepted for return. The material must be returned in the original package, F.O.B. destination freight prepaid. Credit for returned material will be issued in accordance with the following guidelines: a) No Return Material Authorization will be issued for less than $200.00 per line item, b) No material will be accepted for return in the month of December, c) ACA reserves the right to apply a $50.00 charge or 25% of the original invoice price, whichever is greater, d) credit will be issued less any charges necessary to rework and/or repackage material to resalable condition. All returned material is subject to incoming inspection, before nal disposition is determined

www.AFLtele.com/aca 1.800.866.7385

Alcoa Conductor Accessories

A division of AFL Telecommunications