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TABLE OF CONTENTS 1. OBJECTIVE ............................................................................................................................................................3

2. SUMMARY.............................................................................................................................................................3

3. CONCLUSION ........................................................................................................................................................3

4. MATERIAL PROPERTIES...................................................................................................................................3

4.1 SMOKE EMISSION 4.2 ACID GAS EMISSION 4.3 LOW TEMPERATURE FLEXIBILITY

5. ELECTRICAL PROPERTIES ..............................................................................................................................5

5.1 SPACING OF INSULATED BUSBARS 5.2 PROTECTION AGAINST FLASHOVER DUE TO ACCIDENTAL BRIDGING 5.3 CORONA EVALUATION AT RATED VOLTAGES

6. HEAT DISSIPATION AND SHORT TERM OVERLOAD................................................................................8

7. FLAMMABILITY...................................................................................................................................................9

7.1 FLAMMABILITY ANSI IEEE 37.20 7.2 FLAMMBILITY UL 94 HORIZONTAL BURN

8. MECHANICAL DAMAGE..................................................................................................................................11

9. LONG TERM WEATHERING AND THERMAL AGING..............................................................................12

9.1 FLUORESCENT ULTRA VIOLET RADIATION RESISTANCE 9.2 THERMAL ENDURANCE

APPENDIX I PRODUCT PERFORMANCE SPECIFICATION PPS 3010/04 .................................................15

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1. OBJECTIVE

This report documents testing performed to qualify BBIT heat shrinkable bus insulation tubing. This re-qualification testing was performed due to a change made to the compound used to manufacture BBIT tubing. A raw material used in the compound was discontinued by its supplier and replaced with a comparable alternative. As part of the reformulation effort, minor changes were also made to improve long term aging performance.

2. SUMMARY

TE Connectivity supplies busbar insulation products designed for enclosed and exposed bus work in switch gear, substations, and other electrical apparatus to provide flashover protection against accidental temporary bridging of conductors. BBIT tubing can be used to insulate circular and rectangular copper or aluminum busbars and used as insulation for cable to bus connections in switchgear or transformers. The BBIT heavy-wall tubing is used where maximum clearance reduction or up to 36 kV insulation is required. BPTM medium –wall tubing is used where some clearance reduction or 25 kV insulation is required.

3. CONCLUSION

BBIT tubing successfully passed all electrical, mechanical, thermal and material tests described in this report. Test results confirm the performance of BBIT tubing has not been adversely impacted by the changes made to the compound. The BBIT tubing met or exceeded test requirements. Impulse, AC-withstand, DC withstand, and discharge-extinction tests verified no changes to recommended minimum separations of BBIT insulated busbars are needed as a result of the changes made to the material. Tests performed to establish values for the minimum clearance required for phase/phase and phase/ground on busbars insulated with BBIT are documented in test reports UVR-8136 & UVR-8137.

BBIT busbar insulation tubing is qualified for use on both aluminum and copper circular or rectangular busbars. The BBIT tubing provides insulation enhancement and protection against flashover and accidental bridging for indoor and outdoor applications.

4. MATERIAL

All qualification tests documented in this test report were performed on standard production BBIT tubing identified as:

BBIT 100/40-A/U, PT10118, Lot EP41651

BBIT and BPTM tubing material property requirements are documented in Product Performance Specification (PPS) 3010/04 (See Appendix 1).

BBIT Tubing material passed all PPS 3010/04 material requirements. Data documented in internal report number 4991.

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4.1 SMOKE EMISSION

4.1.1 Smoke Emission Test Method

The smoke index of BBIT tubing was determined by TE Connectivity, Swindon, U.K., W+C Fire Science Labs in accordance with TE Connectivity Master Specification PPS 3010, Section 4.21. Testing was performed using a Stanton and Redcroft test chamber in accordance with NES 711, flaming mode.

4.1.2 Smoke Emission Test Results

The smoke index of BBIT tubing is 36.9. BBIT does not produce large amounts of smoke when burned.

4.2 ACID GAS GENERATION

4.2.1 Acid Gas Generation Test Method

The acid gas generation test was performed by TE Connectivity, Swindon, U.K., WC Fire Science Labs in accordance with Master Specification PPS 3010, Section 4.23, reference NES 713.

4.2.2 Acid Gas Generation Test Results

The BBIT had less than 1.61mg/g or less than 0.2% by weight acid gas generation.

4.3 LOW TEMPERATURE FLEXIBILITY

4.3.1 Low Temperature Flexibility Test Method

The low temperature flexibility test was performed in accordance with Master Specification PPS 3010, Section 4.23ASTM D2671 (Procedure C). Five 300 mm long by 6.5 mm wide strips were cut from recovered product in the machine direction and placed into a (-403)C cold chamber along with a 76 mm diameter mandrel. After 4 hours and without removing the mandrel or test specimens from the chamber, each test specimen was wrapped 360 degrees around the mandrel within 102 seconds. The test specimens were then removed from the cold chamber and visually examined for cracks.

4.3.2 Low Temperature Flexibility Test Results

Following four hours conditioning at -40°C, none of the BBIT tubing samples exhibited any cracks or splits after being wrapped around the mandrel.

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5. ELECTRICAL PROPERTIES

5.1 SPACING OF INSULATED BUS-BARS

5.1.1 Spacing of Insulated Rectangular Busbars Test Method

Tests were carried out on BBIT 100/40 tubing installed on 102 mm x 10 mm (4" x 3/8") rectangular aluminum bus to provide the minimum product application wall thickness. A metal sheet was used to simulate an earth plane. The bars were tested phase to phase (bus-bar to bus-bar) and phase to ground (bus-bar to metal sheet) for impulse, 1 minute and 4 hour AC, and 30 minute DC withstand tests (See Figure 1 for test set-up schematic). These electrical tests are designed to verify the minimum recommended bus spacing’s required for phase to phase and phase to ground for the rated voltages listed in Table 1. The impulse voltage withstand tests were performed using an IEC-60 (IEEE-4-1995) standard wave shape with a 1.2 microsecond rise time and a 50 microsecond fall off time. Test specimens were subjected to 10 positive and 10 negative impulses. The limited number of busbar configurations tested was designed to cover the range of rated voltages and BBIT recommended spacings provided in the TE Connectivity BBIT tubing selection guides.

Table 1. Test Voltages used to Qualify BBIT Recommended Spacing for Rectangular Bus

Rated Voltage

(kV)

ph-ph spacing (mm)

ph-gnd spacing (mm)

Impulse Test Voltage (kV)

1 min AC (kV)

4 hr AC (kV)

30 min DC (kV)

12 35 45 95 35 24 48 17.5 55 65 110 45 36 72 24 70 100 150 55 48 96 36 140 190 200 75 72 144

5.1.2 Spacing of Insulated Rectangular Busbars Test Results

All test specimens withstood the required voltages with no breakdown, flashover, or audible corona.

5.1.3 Spacing of Insulated Round Busbars Test Method

Tests were carried out on BBIT 100/40 tubing installed on 76 mm (3") diameter round aluminum bus to provide the minimum product application wall thickness. A metal sheet was used to simulate an earth plane. The bars were tested phase to phase (bus-bar to bus-bar) and phase to ground (bus-bar to metal sheet) for impulse, 1 minute and 4 hour AC, and 30 minute DC withstand tests. These electrical tests are designed to verify the minimum recommended bus spacing’s required for phase/phase and phase/ground for the rated voltages listed in Table 2. The impulse voltage withstand tests were performed using an IEC-60 (IEEE-4-1995) standard wave shape with a 1.2 microsecond rise time and a 50 microsecond fall off time. Test specimens were subjected to 10 positive and 10 negative impulses. The limited number of busbar configurations tested was designed to cover the range of rated voltages and BBIT recommended spacings provided in the TE Connectivity BBIT tubing selection guides.

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Table 2. Test Voltages used to Qualify BBIT Recommended Spacing for Round Bus Rated

Voltage (kV)

ph-ph spacing (mm)

ph-gnd spacing (mm)

Impulse Test Voltage (kV)

1 min AC (kV)

4 hr AC (kV)

30 min DC (kV)

12 30 40 95 35 24 48 17.5 45 60 110 45 36 72 24 60 90 150 55 48 96 36 100 160 200 75 72 144

5.1.4 Spacing of Insulated Round Busbars Test Results

All test specimens withstood the required voltages with no breakdown, flashover, or audible corona.

Figure 1. Spacing of Insulated Rectangular/Round Busbars Test Set-Up Schematic Ph-Ph

Ph-Grd

305mm 1200mm 305mm HV HV

5.2 PROTECTION AGIANST FLASHOVER DUE TO ACCIDENTAL BRIDGING

5.2.1 Protection Against Flashover Due To Accidental Bridging Test Method

Tests were carried out on BBIT 100/40 tubing installed on 102 mm x 10 mm (4" x 3/8") rectangular aluminum bus to provide the minimum product application wall thickness. To simulate the busbar being bridged by a bare bar, a 100 mm copper mesh electrode was wrapped around the BBIT tubing and connected to ground. Stress control tubing installed to eliminate the high field at the edge of the electrode. The voltage on the bar was increased at a rate of 2 kV per second up to 36 kV. The voltage was held at 36 kV for 1 minute. The voltage on the bar was then increased in increments of 2 kV with a 1 minute dwell at each voltage until breakdown occurred.

5.2.2 Protection Against Flashover Due To Accidental Bridging Test Results

All samples withstood 36 kV for one minute. Breakdown occurred between (40 – 47) kV.

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Figure 2. Protection Against Flashover Due Accidental Bridging Test Set-Up Schematic

5.3 CORONA EVLAUATION AT RATED VOLTAGES

5.3.1 Corona Evaluation at Rated Voltages Test Method

To verify the bus system will be free of detectable corona at the highest operating voltages, a partcial discharge detector was used to measure pico coulombs (pc) at the rated voltages using the busbar recommended phase to phase and phase to ground spacings. The measured pc was compared to that of un-insulated busbars using the recommended spacings for phase to ground at the rated voltages. (See Table 3). Tests were carried out on BBIT 100/40 tubing installed on 102 mm X 10 mm rectangular bus. A metal sheet was used to simulate the earth plane.

Table 3. Corona Evaluation at Test Voltages for Rectangular Busbars Rated Voltage

(kV) Uninsulated ph-gnd

Air Clearance (mm)

BBIT Clearance ph-ph spacing

(mm)

BBIT Clearance ph-gnd spacing

(mm) 12 (IEC) 120 35 45

17.5 (IEC) 160 55 65 24 (IEC) 220 70 100 36 (IEC) 320 140 190

5.3.2 Corona Evaluation at Rated Voltages Test Results

The bus systems tested were all free of detectable corona at the highest operating voltages described in Table 3. The measured partial discharge for both un-insulated busbars and insulated busbars using the spacings described in Table 3 were all less than 1 pc.

HV BBIT SCTM

Copper Mesh Electrode

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6. HEAT DISSIPATION AND SHORT TERM OVERLOAD

6.1 Heat Dissipation Test Method

A 1.8 meter long copper busbar insulated with BBIT 100/40 and a 1.8 meter long bare copper busbar were connected using two 0.9 meter long copper busbars to form a circuit. Thermocouples, three each, were attached to the metal surface of both 1.8 meter long bus-bars. A current transformer was used to induce a current of 1600 amps The temperature rise at the metal surface of both 1.8 meter long insulated and un-insulated busbars was measured every 5 minutes and recorded using a temperature monitoring system. Total test time was five hours.

6.2 Heat Dissipation Test Results

Once the temperature of the busbars stabilized, the BBIT insulated busbar was an average of 15 degrees Celsius lower in temperature than the bare busbar. See Graph 1. Average Busbar Temperature vs. Time.

Graph 1. Busbar Temperature vs. Time at 1600 Amps

BBIT Heat DissipationBusbar Temperture vs Time

0

10

20

30

40

50

60

70

80

0 20 40 60 80 100

120

140

160

180

200

220

240

260

280

300

Time (Minutes)

Tem

pera

ture

(°C

)

Bare BusbarBBIT Insulated Busbar

6.3 Short Term Overload Test Method

Tests were carried out on BBIT 100/40 tubing installed on 76 mm (3") diameter round aluminum busbar. The insulated busbar was heated to 200 degrees Celsius using a current transformer. The temperature of the insulated busbar was maintained at 200 degrees Celsius for 30 minutes.

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6.4 Short Term Overload Test Results

All three BBIT tubing test specimens exhibited no splitting, deformation, or visual damage following 30 minutes at 200 degrees Celsius.

Figure 3. Heat Dissipation and Short Term Overload Test Set-Up Schematic

7. FLAMMABILITY

7.1 FLAMMABILITY ANSI IEEE STANDARD C37.20

7.1.1 Flammability ANSI IEEE Standard C37.20 Test Method

Flammability testing was performed according to ANSI IEEE C37.20. Testing was performed on three 50.8 cm long BBIT 100/40 tubing samples. Tubings were recovered onto 67 mm diameter copper mandrels. Each sample was positioned vertically in the test chamber. A 13 mm wide piece of indicator tape was applied to the tubing so that the lower edge was 25 cm above the point at which the inner blue cone of the test flame was applied. A burner while in a vertical position was adjusted to produce a 12.7 cm flame with a 3.8 cm inner blue cone. The burner was then mounted onto a 20-degree block and positioned so that the tip of the blue flame was in contact with the tubing 25 cm below the bottom edge of the indicator tape. The flame was applied for 15 seconds then removed for 15 seconds. This process of 15 seconds flame on followed by 15 seconds flame off was repeated four times for a total of five flame applications. The duration of burning of the test specimen after the fifth flame application and whether the sample conveyed flame was recorded.

7.1.2 Flammability ANSI IEEE Standard C37.20 Test Results

All three BBIT tubing test specimens immediately self extinguished following the fifth flame application. None of the test specimens conveyed flame.

Bare Copper Bar

BBIT Insulated Copper Bar

Current Transformer

Thermocouples to Multichannel Thermometer

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Figure 4. ANSI IEEE Standard C37.20 Test Set-Up Schematic

7.2 FLAMMABILITY UL 94 HORIZONTAL BURNING

7.2.1 Flammability UL 94 Horizontal Burning Test Method

Test specimens (125 mm X 13 mm) were removed from recovered BBIT Tubing. The test specimens were marked with two lines, 25mm and 100 mm from the end that was ignited. Test specimens were clamped with the longitudinal axis horizontal and the transverse axis inclined at 45 degrees. Wire gauze was clamped 10 mm beneath the test specimen. A 20 mm blue flame was applied to the sample for 30 seconds. After 30 seconds, the flame was removed from the test specimen. If the specimen continued to burn and the flame reached the 25 mm mark, the time in seconds was recorded for the flame to propagate from the 25mm mark to the 100 mm mark or until the flame extinguished. If the specimen does not self extinguish before reaching the 25 mm mark, the linear burning rat is calculated. Otherwise, the time until the flame disappears is recorded. Linear burning rate, V, in millimeters per minute is calculated using the equation:

V = to L/t In which: V is the linear burning rate in mm/minute L is the damaged length in mm T is the time in seconds

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UL 94 HB criteria: A material classified as UL HB shall: a) Not have a burning rate exceeding 40 mm per minute over a 75 mm

span for specimens having a thickness of 3.0-13 mm, or b) Not have a burning rate exceeding 75 mm per minute over a 75 mm

span for specimens having a thickness less than 3.0 mm, or c) Cease to burn before the 100 mm reference mark.

7.2.2 Flammability UL 94 Horizontal Burning Test Results

The BBIT tubing passed the UL 94 HB test criteria. The BBIT tubing has an average linear burning rate of 13.6 mm per minute.

Figure 5. ANSI IEEE Standard C37.20 Test Set-Up Schematic

8. MECHANICAL DAMAGE

8.1 Mechanical Damage Test Method

BBIT tubing was recovered on to 102 mm x 10 mm rectangular bus. A 1 kg weight with a 25 mm radius was dropped ten times onto each test specimen from a 1 meter height. The impacts were made at different locations along the center section of the busbar. Following impacts, the test specimens were subjected to an AC withstand test at 25 kV for 1 minute using a copper mesh electrode. The copper mesh electrode was wrapped to ensure the impacted areas were covered by the copper mesh. These same test specimens were then dropped onto a concrete floor ten times from a 2 meter height. Following the second set of impacts, the test specimens were again tested at 25 kV for 1 minute.

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8.2 Mechanical Damage Test Results

Following the 1 kg weight impacts, slight indentions could be seen at the points of impact. Following the BBIT insulated busbars being dropped from a 2 meter height, scuff marks and scratches could be seen. All three BBIT tubing test specimens exhibited no dielectric breakdown following both 25 kV AC withstand tests.

9. LONGTERM WEATHERING AND THERMAL AGING

9.1 FLUORESCENT ULTRA VIOLET RADIATION RESISTANCE

9.1.1 Fluorescent Ultra Violet (UV) Radiation Resistance Test Method

Test samples were removed from recovered BBIT tubing and placed into a UV light apparatus equipped with UVA-340 lamps (simulates direct solar UV radiation with wavelengths between 315 nm and 400 nm). UV testing was performed according to ASTM-G154 “Standard Practice for Operating Fluorescent Light Apparatus for UV Exposure of Nonmetallic Materials”. UV lamps and test specimens were rotated in accordance with ASTM 4329 “Standard Practice for Operating Light and Water Apparatus (Fluorescent UV and Condensation Type) for Exposure of Plastics”. Test plaques were exposed to repetitive cycles of 8 hours UV-A at 60C followed by 4 hours condensation at 50C. Test plaques were periodically removed from the test chamber and ultimate tensile strength and ultimate elongation properties evaluated. Test duration is 15000 hours of UV-A exposure. This correlates to a total test time of 22,500 hours. Ultra violet radiation testing is currently underway. At this time, BBIT tubing has been exposed to greater than 2000 hours of UV-A exposure (3000 hours total test time). The 2000 hour interim test results are report below. This report will be updated at the completion of the test.

9.1.2 Fluorescent Ultra Violet (UV) Radiation Resistance Interim Test Results

Ultra violet radiation testing is currently underway. This report will be updated at the completion of the test.

Following 2000 hours of UV-A exposure, the BBIT tubing material’s ultimate elongation is greater than 450%. This report will be updated at the completion of 15000 hours of UV-A exposure.

9.2 THERMAL ENDURANCE

9.2.1 Thermal Endurance Test Method

Test specimens were removed from recovered BBIT tubing in the longitudinal direction. BBIT tubing test specimens were thermally aged in forced air ovens at 150°C, 160°C, and 170°C. Groups of five specimens were removed at selected times and measured for tensile strength and ultimate elongation. The BBIT tubing thermal endurance was determined according to IEC 216 using 100% ultimate elongation as the design end-of-life criteria.

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9.2.2 Thermal Endurance Test Results

According to IEC 216, a material’s thermal endurance is defined as the continuous service temperature at which the material will last 20,000 hours. Using three aging temperatures 150C, 160C, and 170C the thermal endurance of BBIT tubing was calculated to be 127C. The time to reach 100% ultimate elongation for each temperature can be seen in Table 4 and Graph 2. In Graph 3, times to reach the end-of-life were plotted on a logarithmic scale and the temperatures were plotted as the reciprocal of the absolute temperature in degrees Kelvin. An extrapolation of the data plotted (Graph 3) indicates that the material will retain 100% ultimate elongation after 20,000 hours at 127C (shown on plot), 20 years at 111C, and 40 years at 105C.

Table 4. Time -Temperature Relationship of BBIT using 100% Ultimate Elongation as End Point Temperature (C) Time (hr.) 170 246 160 868 150 1957 Graph 2. BBIT Oven Aging Data

BBIT Thermal Aging

0

100

200

300

400

500

600

700

0 500 1000 1500 2000 2500

Time (hours)

Ulti

mat

e El

onga

tion

(%)

170C160C150C

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Graph 3. BBIT Arrhenius Plot

BBIT Thermal Endurance

1

10

100

1000

10000

100000

0.0015 0.002 0.0025 0.003

1/T (K^-1)

Hour

s to

100

% U

ltimat

e El

onga

tion

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Appendix I. Material Product Performance Specification PPS 3010/04