This article was posted 01/22/2008 and is most likely outdated.

Aluminum – The Other Conductor – Revisited
 

 

Subject - Aluminum – The Other Conductor – Revisited

January 22, 2008
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Aluminum – The Other Conductor – Revisited

 

imageLast March we sent out a newsletter titled Aluminum – The Other Conductor. This was a hot topic which received many comments and sparked a lot of discussion. A newsletter member recently posed an inquiry sparked by this newsletter and we thought it best to send this to all of you in the hopes that he may get his question answered:

 

 

I have just breezed through parts of this forum and the comment Mar 24-07 2041hrs EDT is one that resonated with my current ponderance relating to the increasing pressures in our industry to re-accept aluminum bus in high current (3000-7000 amp) switchboard equipment. I work in a large institutional organization that has 100+ Multistorey buildings and an aggressive building program at present. Historically we have wanted only tin or silver plated copper bussing in equipment. Now the Sales & Consultant pressure is on from a cost, availability and delivery standpoint to go all out aluminum.


My concern is that many boards once energized are never shutdown for maintenance. They run for decades with intense occupant pressure (particularly where medical procedures are performed) never to shut down.

Now tin or silver plated aluminum are being fiercely promoted and argued to be safe. In the kinds of circumstances indicated above and in the March 24. 07 posting - I fear that short term interests may lead to big problems for us down the road.

My inquiry is: Are there any scientific or historic studies that offer support either for or against aluminum and have current technological advances eliminated the concerns of the past for: bus to bus, bus to breaker, breaker to cable connections in the aluminum world?

Please offer comment - publication / study info - thanks!

 

Simply post your comments to this newsletter as usual and this inquirer will receive them.

 

 

 

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Comments
  • Tin plated aluminum box lugs ( the usual kind in a lot of 120 volt to 600 volt stuff ) is a proven product and in a lot of environments lives a lot longer than unplated copper lugs.

    SquareD's tin plated aluminum products ( using the Alstan 80 process ) are also proven. I would stay away from silver plating because silver develops a nonconductive black tarnish. Silver also has some other problems such as turning into a conductive metal wool when exposed to hydrogen sulfide. There is also some belief that silver can solid to solid diffuse into wire insulation.

    I know someone who has a 23 year old house about 1/2 a mile east of Interstate 271 in Pepper Pike, Ohio. The catalytic converters are already eating the copper wiring that is inside of his house. There is a reason why there are antioxidant compounds that are for use with copper wire.

    Every instance of where I have hooked up a plastics machine or air compressor with aluminum shows that all you have to do is to fan out the wire strands, cut off the sharp tips, clean each strand with #220 silicon carbide abrasive paper, and then grease each strand with antioxidant compound. There are also issues such as overstripping the conductor so that you can have a strand bending area and using a screwdriver shaft to establish a bending radius and using a hose clamp to recompress the wire strand and then chamfering the outside strand with a file so that they will slipp into the lugs but that is the general idea. Compact stranded wire strand have some concave surfaces that are difficult to clean but I have found that if I hold 1 end of a silicon carbide paper strip with my little, ring, middle fingers and use my thumb and index fingers to press the other end around the wire strand I get excellent results.

    The one problem that I have not licked is cleaning antioxidant off of my tools and hands in the field without having toi expose my hands to brake cleaning spray.

    Oh yeah, Sefcor makes lugs that you weld to aluminum conductor with a tungsten inert gas welder. This simplifies the silicon carbide paper-elbow grease-electrical grease problem to 2 flat surface each lug. I asked Alcan about this and they said that I should bridge the wires strand using 4043 filler rod.

    You can also get lugs that you exothermically weld to copper wire. You would still need to use silicon carbide paper to clean off copper oxide after the lug cools.

    Michael R. Cole

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